Harley Davidson 2013 Sportster Models. Service Manual — page 26
REMOVAL
Mufflers and Exhaust Pipes
NOTE
See
. Vehicles with mid controls are equipped with
an extra heat shield (2) on the rear exhaust pipe.
1.
See
. Remove heat shields:
a.
Models with Mid Controls:
Remove worm drive
clamps (13) from heat shield (12) completely. Remove
bottom heat shield.
b.
All Models:
Open worm drive clamps (13) and
remove exhaust pipe heat shields (11, 12).
c.
HDI, England, Asia Pacific, India, Japan, Brazil
Models:
Open worm drive clamps (15) and remove
muffler heat shields (14).
2.
Unplug O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to the ECM caddy on the left.
3.
Remove nuts (10) from front and rear cylinder head
exhaust studs.
4.
Remove flanged bolts (16) securing front and rear mufflers
(1, 2) to muffler interconnect bracket (5).
5.
Loosen Torca muffler clamp assemblies (6) on front and
rear mufflers. Remove mufflers. Discard muffler intercon-
nect gaskets (19).
6.
Remove and discard Torca clamps.
NOTE
New Torca muffler clamps have eliminated the need for silicone
or graphite tape during assembly. Always use new clamps
during installation to maintain sealing integrity and prevent
leakage.
7.
Remove nut (22) and screw (23) from exhaust pipe clamp
(20). Separate exhaust pipe clamp from clamp bracket
(21).
8.
Remove front and rear exhaust pipes (3, 4). Slide exhaust
pipe clamp off rear exhaust pipe.
9.
Remove exhaust port gasket (7), retaining ring (8) and
exhaust pipe flange (9) from each exhaust pipe. Discard
gasket.
10. Remove O2 sensor assemblies (27, 28) from front and
rear exhaust pipes. Discard seal rings (29). See
1
2
3
4
sm04380
1. Top heat shield
2. Bottom heat shield
3. Upper worm drive clamp
4. Lower worm drive clamp
Figure 4-66. Rear Exhaust Pipe Heat Shields: Vehicles with
Mid Controls
Muffler Interconnect Bracket
1.
See
. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).
2.
See
. Remove rear brake rod (1) at bell crank
(2).
3.
See
. Remove three screws (17) and washers
(18) securing muffler interconnect bracket (5) to engine
crankcase. Remove muffler interconnect bracket.
2
4
5
6
3
1
sm02202
1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw
Figure 4-67. Sprocket Cover
2013 Sportster Service: Fuel System 4-43
1
5
4
3
2
sm02199
1. Rear brake rod
2. Bell crank
3. Rear brake master cylinder assembly
4. Rear brake pedal
5. Frame
Figure 4-68. Rear Brake Linkage
INSTALLATION
TOOL NAME
PART NUMBER
SNAP-ON SWIVEL BALL SOCKET
EXTENSION
PFSX916
TORQUE VALUE
FASTENER
40.7-44.7 Nm
30-33 ft-lbs
Muffler interconnect bracket
mounting screw: XL Models
13.6-20.4 Nm
120-180
in-lbs
Brake rod to bell crank screw
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket
screw: XL Models
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
39.3-59.7 Nm
29-44 ft-lbs
O2 sensor
20.4-25.8 Nm
15-19 ft-lbs
Muffler to interconnect bracket
screw: XL Models
10.9-13.6 Nm
96-120
in-lbs
Cylinder head exhaust port nut
51.6-58.4 Nm
38-43 ft-lbs
Muffler torca clamp nut
27.1-40.7 Nm
20-30 ft-lbs
Exhaust pipe clamp nut: XL
Models
2.3-4.5 Nm
20-40
in-lbs
Exhaust heat shield clamps
Muffler Interconnect Bracket
1.
See
. Install muffler interconnect bracket (5)
to engine case with three screws (17) and washers (18).
Tighten to 30-33 ft-lbs (40.7-44.7 Nm).
2.
See
. Apply two drops of LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND SEALANT
(blue) to rear brake rod ball stud screw. Attach rear brake
rod (1) to bell crank (2). Tighten screw to 120-180
in-lbs
(13.6-20.4 Nm).
3.
See
. Install sprocket cover (1). Install but do
not tighten the screws (2, 3). Note that long screw goes
in top hole, short screw in bottom hole.
4.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120
in-lbs
(9.0-13.6 Nm).
Exhaust Pipes and Mufflers
NOTES
•
To facilitate installing exhaust pipe header nuts, use
SNAP-ON SWIVEL BALL SOCKET EXTENSION (Part
No. PFSX916).
•
If reusing the O2 sensors, apply a thin coat of ANTI-SEIZE
LUBRICANT to the threads prior to installation. Do not
use any other grease or sealant product on sensor threads.
•
The electrical connector must also be clean and free of
dielectric grease.
1.
See
. If the front and rear O2 sensor assem-
blies (27, 28) are being reused, install
new
seal rings (29)
onto each sensor. Apply a thin coat of ANTI-SEIZE LUB-
RICANT to the sensor threads.
4-44 2013 Sportster Service: Fuel System
2.
Install sensor assemblies into front and rear exhaust pipes.
Tighten to 29-44 ft-lbs (39.3-59.7 Nm). See
.
3.
Place exhaust pipe flange (9), exhaust gasket retaining
ring (8) and
new
exhaust port gasket (7) over front end of
each exhaust pipe (3, 4). Position flange so that inside
counterbore faces cylinder head exhaust port.
4.
Position front ends of front and rear exhaust pipes into
front and rear cylinder heads, respectively. Position holes
in flanges over mounting studs and loosely install nuts
(10). Do not tighten nuts at this time.
5.
Install exhaust pipe clamp (20) on rear exhaust pipe (4)
with square hole facing down. Assemble exhaust pipe
clamp to exhaust pipe clamp bracket (21) with screw (23)
and acorn nut (22). Verify that the bracket fits between
ends of clamp. Do not tighten at this time.
6.
Install
new
muffler interconnect gaskets (19) in intercon-
nect mating holes in mufflers (1, 2).
7.
Place
new
Torca clamp assemblies (6) over slotted end
of each muffler. Install each muffler onto the end of its
respective exhaust pipe.
8.
Rotate both mufflers until their mounting bosses line up
with holes in muffler interconnect bracket. Carefully mate
each muffler with exhaust port in interconnect bracket.
Loosely install flanged bolts (16). Do not tighten at this
time.
9.
Tighten exhaust system fasteners in the following
sequence:
a.
Tighten four flanged bolts securing mufflers to inter-
connect bracket to 15-19 ft-lbs (20.4-25.8 Nm).
b.
Tighten four nuts at cylinder head exhaust studs to
96-120
in-lbs
(10.9-13.6 Nm).
c.
Tighten two Torca clamps to 38-43 ft-lbs (51.6-58.4
Nm).
d.
Tighten rear exhaust pipe clamp nut (22) to 20-30 ft-
lbs (27.1-40.7 Nm).
10. Plug in O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to the left side of the ECM caddy. See
11. Install heat shields:
a.
Open worm drive clamps (13) and install heat shields
(11, 12) on exhaust pipes. Position each clamp so
that screw is on the outboard side in the most
accessible position.
b.
Models with Mid Controls:
See
. Tighten
lower worm drive clamp (4) a few turns. Slide lower
portion of bottom heat shield (2) into lower worm drive
clamp. Engage upper portion of bottom heat shield
into upper worm drive clamp (3).
c.
All Models:
Tighten all exhaust pipe heat shield
clamps to 20-40
in-lbs
(2.3-4.5 Nm).
d.
HDI, England, Asia Pacific, India, Japan and Brazil
Models:
Open worm drive clamps (15). Install the
muffler heat shields (14). Position each clamp so that
screw is on the outboard side in the most accessible
position. Tighten clamps securely.
2013 Sportster Service: Fuel System 4-45
4.14
EXHAUST SYSTEM: XR 1200X
GENERAL
TOOL NAME
PART NUMBER
SNAP-ON WRENCH
PFSX916
To facilitate removing exhaust pipe header nuts, use SNAP-
ON WRENCH (Part No. PFSX916).
23
1
2
22
3
4
5
6
7
20
21
19
11
10
8
9
12
13
14
16
15
17
18
sm05463
17.
9.
1.
Flanged nut
Sleeve
Fastener, rear muffler mount
2.
18.
10.
Fastener, mount to frame
Lower clamp
Fastener, interconnect bracket
(3)
3.
19.
Fastener, front muffler mount
Muffler gasket (2)
11.
20.
Interconnect bracket
4.
Lower muffler
Flat washer
5.
21.
12.
Grommet, front mount (2)
Upper muffler
Nut (4)
13.
6.
22.
Retaining ring (2)
Fastener, front muffler mount
(2)
Rear muffler mount
23.
14.
Bolt, muffler-to-muffler (2)
Exhaust port gasket (2)
7.
15.
Front muffler mount
Exhaust pipe flange (2)
16.
8.
Carriage bolt
Washer-nut
Figure 4-69. Exhaust System: XR 1200X
REMOVAL
Mufflers
1.
See
. Remove forward muffler mount fastener
(3) and washer-nut (8).
2.
Remove two bolts (23) fastening mufflers together.
3.
Slide upper muffler (21) back off header pipe to remove.
4.
Remove rear muffler mount fastener (1).
4-46 2013 Sportster Service: Fuel System
5.
Rotate lower muffler (20) counterclockwise to disengage
from the rear mount (22) and slide back off header pipe
to remove.
6.
Remove mount grommets (5) and sleeve (9).
7.
Inspect rear mount (22) and replace if damaged.
8.
Inspect muffler seals (19) and replace if necessary:
a.
Pull seal out of muffler using a hook-type tool.
b.
Push
new
seal into place being careful not to distort
or damage the new seal.
Header Pipes
1.
Remove mufflers.
2.
Disconnect O2 sensor connectors. Remove sensor if
necessary. See
.
3.
See
. Loosen or remove head pipe heat shields
to gain access to header pipe flange nuts (12).
4.
Remove flange nuts (12) and pull flanges (15) off from
studs.
5.
Remove nut (17) and carriage bolt (16) from lower clamp
(18).
NOTE
Be careful not to drop or hit header pipe assembly. Damage
to the catalytic converter may result.
6.
Remove header pipe assembly from vehicle.
7.
Inspect exhaust port gasket (14) and replace if necessary.
a.
Pry gasket from exhaust port in cylinder head being
careful not to damage the bore.
b.
Push
new
gasket into place with the larger ID facing
the header pipe, as shown in the inset in
.
8.
Remove retainer rings (13) and flanges (15) if necessary.
9.
If necessary, remove mount brackets (7, 22) and intercon-
nect bracket (11).
INSTALLATION
TORQUE VALUE
FASTENER
20.3-27.1 Nm
15-20 ft-lbs
Muffler mount to frame, rear
fastener: XR 1200X
61.0-67.8 Nm
45-50 ft-lbs
Muffler mount to frame, front
fastener: XR 1200X
40.7-44.7 Nm
30-33 ft-lbs
Interconnect bracket to frame
fastener: XR 1200X
10.8-13.6 Nm
96-120
in-lbs
Exhaust flange nut: XR 1200X
40.7-44.7 Nm
30-33 ft-lbs
Exhaust clamp, lower nut: XR
1200X
13.6-20.3 Nm
120-180
in-lbs
Muffler to front muffler mount
fastener: XR 1200X
13.6-20.3 Nm
120-180
in-lbs
Muffler to muffler bolt: XR
1200X
13.6-20.3 Nm
120-180
in-lbs
Muffler to rear muffler mount
fastener: XR 1200X
2.3-4.5 Nm
20-40
in-lbs
Exhaust heat shield clamps
1.
See
. If removed, install flanges (15) and
retaining rings (13).
2.
If removed, install rear mount (22), front mount (7) and
interconnect bracket (11).
a.
Tighten fasteners (2) to 15-20 ft-lbs (20.3-27.1 Nm).
b.
Tighten fasteners (6) to 45-50 ft-lbs (61.0-67.8 Nm).
c.
Tighten fasteners (10) to 30-33 ft-lbs (40.7-44.7 Nm).
NOTE
Do not damage exhaust port gaskets (14) when positioning
header pipes in exhaust port area.
3.
Install
new
exhaust port gaskets (14).
4.
Install head pipe assembly in position and loosely secure
lower clamp (18) with carriage bolt (16) and flange nut
(17).
5.
Install flanges (15) and finger-tighten nuts (12). Do not
tighten until mufflers are installed.
6.
Install mufflers.
7.
Place lower muffler (20) on header pipe. Rotate until rear
mount fastener (1) can be installed. Loosely install fastener
(1).
8.
Place upper muffler (21) on header pipe.
9.
Install muffler-to-muffler bolts (23) finger-tight.
10. Install grommets (5), sleeve (9), fastener (3), washer (4)
and washer nut (8). Tighten finger-tight.
11. Tighten the exhaust flange nuts (12) to 96-120
in-lbs
(10.8-13.6 Nm) in the following sequence:
a.
The front exhaust pipe lower exhaust flange nut
b.
The front exhaust pipe upper exhaust flange nut
c.
The rear exhaust pipe lower exhaust flange nut
d.
The rear exhaust pipe upper exhaust flange nut
2013 Sportster Service: Fuel System 4-47
12. Verify the exhaust header pipes do not contact the drive
belt idler pulley. Verify that there is sufficient clearance for
proper operation of the rear brake pedal. Tighten nut (17)
to 30-33 ft-lbs (40.7-44.7 Nm).
13. Tighten fastener (3) to 120-180
in-lbs
(13.6-20.3 Nm).
14. Tighten muffler to muffler bolts (23) to 120-180
in-lbs
(13.6-20.3 Nm).
15. Tighten rear mount fastener (1) to 120-180
in-lbs
(13.6-
20.3 Nm).
16. Install heat shields. Tighten to 20-40
in-lbs
(2.3-4.5 Nm).
17. Install and connect the O2 sensors. See
.
4-48 2013 Sportster Service: Fuel System
4.15
FUEL INJECTORS
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
in death or serious injury. (000621b)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
XL Models with 4.5 gal
(
17.0 L
)
fuel tank
: Access to the
fuel injectors and fuel rail may be easier if the fuel tank is
raised up as follows:
a.
Remove seat.
b.
Loosen (but do not remove) front fuel tank mounting
screw. Remove rear fuel tank mounting screw,
washers and nut. See
.
c.
Place a clean shop cloth between front of fuel tank
and front fork upper bracket to protect fuel tank finish.
Carefully pivot rear of fuel tank upward and prop in
position with a block of soft wood or other suitable
device.
4.
See
. Unplug engine sub-harness connectors
from fuel injector connectors [84A], [85A] (7, 8).
5.
Remove screw (5) and retaining bracket (2).
6.
If replacing either the fuel supply hose (1) or fuel rail (6),
disassemble as follows:
a.
Hold fuel rail in place.
b.
With a gentle twisting motion, pull fuel supply hose
straight up out of fuel rail.
7.
Hold fuel injectors (9, 10) in place by pressing down on
harness connectors (7, 8) and with a gentle rocking motion,
pull fuel rail off injectors.
8.
With a gentle twisting motion, pull fuel injectors out of
intake manifold (XL models) or induction module (XR
1200X).
9.
Remove and discard O-rings (11).
2
4
5
1
3
sm06857
1. Fuel supply hose
2. Retaining bracket
3. Fuel rail
4. Front fuel injector and connector
5. Rear fuel injector and connector
Figure 4-70. Fuel Injector Assembly Location: XL Models
2013 Sportster Service: Fuel System 4-49
2
5
3
4
1
sm06858
1. Fuel supply hose
2. Retaining bracket
3. Fuel rail (not visible)
4. Front fuel injector and connector
5. Rear fuel injector and connector
Figure 4-71. Fuel Injector Assembly Location: XR 1200X
1
3
4
6
8
10
9
11
7
11
5
2
12
sm06567
1. Fuel supply hose
2. Retaining bracket
3. Sealing washer (only available with fuel supply
hose)
4. O-ring (only available with fuel supply hose)
5. Screw
6. Fuel rail
7. Front injector connector [84A]
8. Rear injector connector [85A]
9. Front fuel injector
10. Rear fuel injector
11. O-ring (4) (provided in repair kit)
12. Intake manifold
Figure 4-72. Fuel Injector Assemblies: XL Models
INSTALLATION
TORQUE VALUE
FASTENER
6.8 Nm
60
in-lbs
Fuel hose retaining bracket
screw
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank fasteners: XL
Models
1.
See
. Apply a thin coat of clean engine oil to
new
fuel injector O-rings (11). Install O-rings onto fuel
injectors (9, 10).
2.
With harness connectors (7, 8) facing up, push fuel
injectors into intake manifold (XL models) or induction
module (XR 1200X).
3.
See
or
. Rotate fuel injectors so
that harness connectors are positioned as shown.
4-50 2013 Sportster Service: Fuel System
4.
Gently press fuel rail onto free end of fuel injectors. Press
fuel rail down until hole in fuel rail molded-in bracket lines
up with mounting hole in intake manifold (12).
5.
If the fuel supply hose and fuel rail were separated in the
disassembly procedure, reassemble:
a.
See
. Inspect sealing washer (3) and O-
ring (4) for damage. If either require replacement,
install a
new
fuel line kit.
b.
Lightly coat O-ring with clean engine oil. Push fuel
supply hose into fuel rail bore until collar on hose is
flush with top of fuel rail.
6.
See
. Install retaining bracket (2) and fastener
(5) as follows:
a.
See
. Orient fuel supply hose so that loc-
ating flange (2) is positioned as shown.
b.
Install retaining bracket (3). Fit the U-shaped opening
in bracket around fuel supply hose and locating
flange.
c.
See
. Secure retaining bracket (2) with
screw (5). Tighten to 60
in-lbs
(6.8 Nm).
NOTES
•
XL Models: See
. The fuel injector harness
leads are mounted between the bracket and induction
module.
•
XR 1200X: See
. Do not route the fuel injector
harness leads between the retaining bracket (2) and
induction module body. Improper routing will result in
chafing of the insulation resulting in poor engine perform-
ance.
7.
Connect engine sub-harness connectors to the fuel
injectors. Verify that the wire harnesses are routed outside
the wings of retaining bracket (2) on XR 1200X.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
8.
XL Models with 4.5 gal
(
17.0 L
)
Fuel Tank:
if the fuel
tank was raised up to gain access to the fuel injectors,
install fuel tank and seat:
a.
Remove prop from under rear of fuel tank.
b.
Lower rear of fuel tank into position.
c.
Install fastener, washer and nut in fuel tank rear
mounting holes.
d.
Tighten front and rear fasteners to 15-20 ft-lbs (20.3-
27.1 Nm).
e.
Install protective caps on screw ends. See
.
f.
Install seat.
9.
Connect fuel hose to fuel pump module. Fill fuel tank.
Check for leaks around fuel pump module. See
.
10. Install main fuse.
11. Close left side cover.
3
1
2
4
sm06568
1. Fuel supply hose
2. Locating flange
3. Retaining bracket
4. Fuel rail
Figure 4-73. Mounting Fuel Hose and Fuel Rail: XL Models
2013 Sportster Service: Fuel System 4-51
4.16
FUEL PUMP
GENERAL
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Do not replace the special Teflon coated fuel pump wiring
with ordinary bulk wire. Ordinary insulation materials can
deteriorate when put in contact with gasoline and cause
an explosion, which could result in death or serious injury.
(00566b)
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
in death or serious injury. (000621b)
Carefully inspect fuel hose for cuts, tears, holes or other
damage. Replace hose if any damage is found. Even a small
hole can cause a reduction in fuel pressure.
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
See
. Unplug fuel pump harness connector
[141] (1), located forward of fuse/relay block on left side
of vehicle.
4.
Drain and remove fuel tank from vehicle. See
or
.
5.
See
. Lay fuel tank upside-down on a soft cloth.
6.
Remove five screws (3).
7.
Carefully lift fuel pump module out of fuel tank. See
. To facilitate removal, tilt module when it is
almost completely free of fuel tank.
8.
See
. Remove and discard cover plate seal
(7).
1
2
4
7
5
6
3
sm06721
1. Fuel pump harness connector [141]
2. Fuel pump
3. Fuel filter housing
4. Sending unit float
5. Quick-connect fitting
6. Cover plate
7. Cover plate seal
Figure 4-74. Fuel Pump Module
4-52 2013 Sportster Service: Fuel System
2
4
1
5
3
12323
1. Fuel tank
2. Fuel pump module
3. Screw (5)
4. Fuel pump harness
5. Quick-connect fitting
Figure 4-75. Fuel Pump Module: All Models
sm01571
Figure 4-76. Removing/Installing Fuel Pump Module: All
Models
DISASSEMBLY
The disassembly procedure consists of the following groups:
•
Pressure regulator and filter housing.
•
Fuel pump assembly and pump bracket.
•
Low fuel level sensor assembly.
•
Fuel pump.
2
4
1
3
sm06722
1. Cable strap (3)
2. Pump assembly clamp
3. Pump bracket
4. Filter housing hose
Figure 4-77. Fuel Pump Cable Straps and Pump Clamp
NOTE
See
. Maintain the relative positions of the wiring
harness cable straps (1) and pump assembly clamp (2).
Pressure Regulator and Filter Housing
1.
See
. Remove cable strap (1) securing wiring
harness to the filter housing hose (4).
2.
See
. Remove ground clip (12) from top of filter
housing (23).
3.
Remove and discard clamp (1). Remove filter housing
hose from top of fuel pump (2).
4.
Remove retaining clip (24) from top of filter housing and
remove pressure regulator (22).
5.
Remove second retaining clip (24) from bottom of filter
housing and remove filter housing. Remove fuel filter ele-
ment (25) from housing.
6.
Remove O-ring (26) from filter housing mount (19).
2013 Sportster Service: Fuel System 4-53
Fuel Pump Assembly and Pump Bracket
1.
See
. Make note of the location of any cable
straps securing wiring harness to the fuel pump bracket
(3). Remove cable straps.
2.
See
. Unplug fuel pump harness connector
[86] (13).
3.
Unplug low fuel level sensor connector from fuel
pump/sender harness (14).
4.
Remove and discard clamp (1). Remove filter housing
hose (11) from top of fuel pump (2).
5.
Remove and discard pump assembly clamp (7). Remove
pump assembly with pump insulator (3) from pump bracket
(5).
6.
Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket.
7.
Remove three screws w/lockwashers (6) and remove
pump bracket from cover plate (9).
Low Fuel Level Sensor Assembly
1.
See
. Make note of the location of cable strap
(1) securing low fuel level sensor connector to filter
housing hose (4). Remove cable strap.
2.
See
. Unplug the fuel pump/sender harness
connector (15) from the low fuel level sensor (17).
3.
Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket (5).
ASSEMBLY
TORQUE VALUE
FASTENER
2.1-4.1 Nm
19-36
in-lbs
Fuel pump bracket mounting
screw
The assembly procedure consists of the following groups:
•
Low fuel level sensor assembly.
•
Fuel pump assembly and pump bracket.
•
Pressure regulator and filter housing.
Low Fuel Level Sensor Assembly
NOTE
The low fuel lamp will not turn off until there is sufficient fuel in
the tank, the ignition switch has been turned off and on and
the motorcycle has begun forward speed.
1.
See
. Install low fuel level sensor assembly
(17) onto pump bracket (5). Secure with push nut (16).
2.
Plug the fuel pump/sender harness connector (15) into
the low fuel level sensor (17).
3.
See
. Secure low fuel level sensor connector
and fuel pump/sender harness to filter housing hose (4)
with cable strap (1).
Fuel Pump Assembly and Pump Bracket
1.
See
. Install pump bracket (5) onto cover plate
(9). Secure with three screws w/lockwashers (6). Tighten
to 19-36
in-lbs
(2.1-4.1 Nm).
2.
Install low fuel level sensor assembly (17) onto pump
bracket. Secure with push nut (16).
3.
Install fuel pump assembly (2) with pump insulator (3) onto
pump bracket. Secure with pump assembly clamp (7) (for
relative position of clamp, see
.)
4.
Install filter housing hose (11) on top of fuel pump. Secure
with clamp (1).
5.
Plug in fuel pump harness connector [86] (13).
6.
See
. Secure fuel pump/sender harness to fuel
pump bracket (3) with cable straps (1).
Pressure Regulator and Filter Housing
1.
See
. Install the
new
O-ring onto filter housing
mount (19).
2.
Install fuel filter element (25) into filter housing (23). Install
filter housing onto filter housing mount. Secure with
retaining clip (24) at bottom of housing, making sure that
clip is oriented exactly as shown in
.
3.
Install pressure regulator (22) on top of filter housing.
Secure with second retaining clip (24), making sure that
clip is oriented exactly as shown in
.
4.
Install filter housing hose (11) on top of fuel pump (2).
Secure with clamp (1).
5.
Install ground clip (12) on top of filter housing.
6.
See
. Secure fuel pump/sender harness to
filter housing hose (4) with cable strap (1).
4-54 2013 Sportster Service: Fuel System
22
23
11
25
26
14
13
16
17
18
19
20
21
14
10
9
8
7
6
5
4
3
2
1
12
24
15
27
27
27
sm01611a
15.
1.
Low fuel level sensor connector
Clamp
2.
16.
Fuel pump
Push nut
17.
3.
Low fuel level sensor
Pump insulator
4.
18.
Cover plate seal
Retaining ring
19.
5.
Filter housing mount
Pump bracket
6.
20.
Screw w/lockwasher (3)
Screw (5)
21.
7.
Fuel outlet quick-connect fitting
Pump assembly clamp
8.
22.
Inlet sock
Pressure regulator
23.
9.
Filter housing
Cover plate
10.
24.
Fuel pump/sender harness connector [141]
Retaining clip (2)
25.
11.
Fuel filter element
Filter housing hose
12.
26.
Ground clip
O-ring
27.
13.
Cable strap
Fuel pump harness connector [86]
14. Fuel pump/sender harness
Figure 4-78. Fuel Pump and Sender Assembly
INSTALLATION
TORQUE VALUE
FASTENER
4.5-5.1 Nm
40-45
in-lbs
Fuel pump module mounting
screw
1.
See
. Install
new
cover plate seal (4) into
groove in cover plate (9).
2.
See
. Carefully install fuel pump module into
fuel tank.
a.
Tilt module.
b.
Lower it into fuel tank.
c.
Straighten module to complete installation.
3.
See
. Install screws. Tighten to 40-45
in-lbs
(4.5-5.1 Nm) in sequence.
4.
Install fuel tank. See
or
.
a.
Verify that the fuel pump harness fits in wire harness
caddy latch clip with loop in harness between latch
clip and fuel pump module.
b.
Plug in fuel pump harness connector [141].
c.
Connect vent hose to fuel tank vent nipple.
5.
Connect fuel hose to fuel tank. Fill fuel tank. Check for
leaks around fuel pump module. See
or
6.
Install main fuse.
7.
Close left side cover.
2013 Sportster Service: Fuel System 4-55
8.
Check for leaks:
a.
Turn ignition switch to ON.
b.
Verify fuel pump is activated.
c.
Check for leaks at quick connect.
d.
Turn ignition switch to OFF.
1
3
4
2
5
sm07444
Figure 4-79. Fuel Pump Module Torque Sequence
4-56 2013 Sportster Service: Fuel System
4.17
FUEL FILTER ELEMENT
GENERAL
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
in death or serious injury. (000621b)
The fuel filter element is located in the fuel pump assembly
inside the fuel tank.
Check fuel system hose and fittings for leaks.
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
2.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
3.
Remove main fuse.
4.
Drain and remove fuel tank. See
or
5.
Remove fuel pump assembly from fuel tank. See
6.
See
. Remove and discard cover plate seal
(6).
7.
Remove retaining clip (4) and lift filter housing (5) off fuel
pump assembly (1).
8.
Remove and discard filter element (3).
INSTALLATION
TORQUE VALUE
FASTENER
4.5-5.1 Nm
40-45
in-lbs
Fuel pump module mounting
screw
1.
See
. Install a
new
O-ring (2).
2.
Install
new
filter element (3) into filter housing (5).
3.
Install filter housing onto base of fuel pump assembly (1).
Secure with retaining clip (4), making sure that clip is ori-
ented right side up, exactly as shown in the figure.
4.
Install
new
cover plate seal (6) into groove in cover plate
(7).
5.
Install fuel pump assembly into fuel tank. Tighten mounting
screws in a cross pattern to 40-45
in-lbs
(4.5-5.1 Nm).
See
6.
Install fuel tank and reconnect fuel hose. See
or
. Fill
fuel tank and carefully check for leaks.
7.
Install main fuse.
8.
Install seat.
9.
Turn ignition switch ON. Verify fuel pump operation.
1
3
6
5
4
2
7
sm06645
1. Fuel pump assembly
2. O-ring
3. Fuel filter element
4. Retaining clip
5. Filter housing
6. Cover plate seal
7. Cover plate
Figure 4-80. Replacing Fuel Filter Element
2013 Sportster Service: Fuel System 4-57
4.18
FUEL PRESSURE TEST
GENERAL
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
The fuel pump delivers fuel to the fuel hose, a cavity in the
induction module that supplies the fuel injectors, and to the
pressure regulator. Excess fuel pressure is bypassed to the
fuel tank through the pressure regulator.
The fuel pump can be turned on with DIGITAL TECHNICIAN
II (Part No. HD-48650).
Improper fuel system pressure may contribute to one of the
following conditions:
•
Cranks, but does not run.
•
Cuts out (may feel like ignition problem).
•
Hesitation, loss of power or poor fuel economy.
TESTING
TOOL NAME
PART NUMBER
FUEL PRESSURE GAUGE
HD-41142
FUEL PRESSURE GAUGE ADAPTER
HD-44061
Connect the Fuel Pressure Gauge
1.
Purge the fuel supply hose and disconnect the fuel supply
hose from the fuel pump module.
a.
XL Models:
See
.
b.
XR 1200X:
See
2.
Connect the fuel pump connector [141].
NOTE
Do not kink the fuel hose when installing or removing fuel
pressure gauge and adapter.
3.
See
. Attach the FUEL PRESSURE GAUGE
ADAPTER (Part No. HD-44061) as follows:
a.
See
. Pull up on sleeve of fuel tank quick-
connect fitting (2) and insert neck of the fuel pressure
gauge adapter (3) into quick-connect fitting.
b.
Push up on bottom of adapter and pull down on sleeve
until it clicks. Tug on adapter to verify that it is locked
in place.
c.
In the same manner, connect vehicle's fuel supply
hose fitting (1) to quick-connect fitting (4) on the
adapter.
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)
4.
Verify that the fuel valve (6) and air bleed petcock on the
fuel pressure gauge are closed.
5.
See
. Remove protective cap from free end of
fuel pressure gauge adapter.
6.
Connect the FUEL PRESSURE GAUGE (Part No. HD-
41142) to the Schroeder valve.
Perform Test
1.
Start and idle engine to pressurize the fuel system. Open
the fuel valve to allow the flow of fuel down the hose of
the pressure gauge.
2.
Purge air from gauge and hose:
a.
Position the clear air bleed tube in a suitable con-
tainer.
b.
Open and close the air bleed petcock to purge the
gauge and hose of air.
c.
Repeat this step several times until only solid fuel
(without bubbles) flows from the air bleed tube.
d.
Close the petcock.
3.
Open and close throttle to change engine speed. Note the
reading of the pressure gauge.
4.
Turn the engine OFF and service as necessary. Refer to
.
3
2
1
sm01654a
1. Quick-connect fitting
2. Protective cap
3. Fuel tank fitting (neck)
Figure 4-81. Fuel Pressure Gauge Adapter (Part No.
HD-44061)
4-58 2013 Sportster Service: Fuel System
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