Harley Davidson 2013 Sportster Models. Service Manual — page 12
2.2
SPECIFICATIONS
TABLES
Chassis
Table 2-1. Dimensions: XL 883 Models
XL 883N
XL 883L
XL 883R
ITEM
mm
in
mm
in
mm
in
1519
59.8
1506
59.3
1524
60.0
Wheel base
99
3.9
97
3.8
142
5.6
Road clearance
653
25.7
648
25.5
693
27.3
Seat height*
*With 180 lb (81.7 kg) rider on seat.
Table 2-2. Dimensions: XL 1200 Models and XR 1200X
XR 1200X
XL 1200V
XL 1200X
XL 1200CB
XL 1200CA
XL 1200C/C ANV
ITEM
mm
in
mm
in
mm
in
mm
in
mm
in
mm
in
1524
60.0
1524
60.0
1519
59.8
1520
59.8
1520
59.8
1520
59.8
Wheel base
150
5.9
120
4.7
99
3.9
110
4.3
110
4.3
110
4.3
Road clearance
742
29.2
676
26.6
660
26.0
676
26.6
676
26.6
676
26.6
Seat height*
*With 180 lb (81.7 kg) rider on seat.
Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can lead to component
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f)
•
GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider, pas-
senger and cargo that can be safely carried.
•
GAWR is the maximum amount of weight that can be
safely carried on each axle.
•
The GVWR and GAWR are shown on the information
plate, located on the frame down tube.
NOTES
•
The maximum additional weight allowed on the motorcycle
equals the Gross Vehicle Weight Rating (GVWR) minus
the running weight. For example, a motorcycle with GVWR
of 1200 lbs (544 kg) having a running weight of 800 lbs
(363 kg), would allow a maximum of an additional 400 lbs
(181 kg) combined weight of the rider, passenger, riding
gear, cargo and installed accessories.
•
For important information regarding tire data and tire
inflation, see
.
Table 2-3. Weights: XL 883 Models
XL 883N
XL 883R
XL 883L
ITEM
kg
lb
kg
lb
kg
lb
256.3
565
260.0
573
255.4
563
Running weight*
197.3
435
193.7
427
198.2
437
Maximum added weight
allowed**
453.6
1000
453.6
1000
453.6
1000
GVWR
152.0
335
152.0
335
154.0
339
GAWR front
301.6
665
301.6
665
300.0
661
GAWR rear
*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this weight.
2013 Sportster Service: Chassis 2-9
Table 2-4. Weights: XL 1200 Models and XR 1200X
XR 1200X
XL 1200V
XL 1200X
XL 1200CB
XL 1200CA
XL 1200C/C ANV
ITEM
kg
lb
kg
lb
kg
lb
kg
lb
kg
lb
kg
lb
259.9
573
251.7
555
257.2
567
260.0
573
260.0
573
264.0
582
Running weight*
193.7
427
201.8
445
196.4
433
193.7
427
193.7
427
189.6
418
Maximum added
weight allowed**
453.6
1000
453.6
1000
453.6
1000
453.6
1000
453.6
1000
453.6
1000
GVWR
154.2
340
152.0
335
152.0
335
152.0
335
152.0
335
152.0
335
GAWR, front
299.4
660
301.6
665
301.6
665
302.0
665
302.0
665
301.6
665
GAWR, rear
*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this weight.
Table 2-5. Capacities: XL 883 Models
XL 883N
XL 883L
XL 883R
ITEM
METRIC
U.S.
METRIC
U.S.
METRIC
U.S.
12.5 L
3.3 gal
17.0 L
4.5 gal
12.5 L
3.3 gal
Fuel tank (total)
2.6 L
2.8 qt
2.6 L
2.8 qt
2.6 L
2.8 qt
Oil tank with filter
0.95 L
1.0 qt
0.95 L
1.0 qt
0.95 L
1.0 qt
Transmission (approximate)
3.0 L
0.8 gal
3.8 L
1.0 gal
3.0 L
0.8 gal
Low fuel warning light
Table 2-6. Capacities: XL 1200 Models and XR 1200X
XR 1200X
XL 1200X/V
XL 1200C/C ANV/CP/CA/CB
ITEM
METRIC
U.S.
METRIC
U.S.
METRIC
U.S.
13.2 L
3.5 gal
7.9 L
2.1 gal
17.0 L
4.5 gal
Fuel tank (total)
2.6 L
2.8 qt
2.6 L
2.8 qt
2.6 L
2.8 qt
Oil tank with filter
0.95 L
1.0 qt
0.95 L
1.0 qt
0.95 L
1.0 qt
Transmission
(approximate)
3.0 L
0.8 gal
2.5 L
0.65 gal
3.8 L
1 gal
Low fuel warning light
Table 2-7. Brake Disc Specifications: XL Models
mm
in
SPECIFICATION
292
11.500
Diameter (front)
260
10.236
Diameter (rear)
5.08
0.200
Minimum thickness (front)
5.84
0.230
Minimum thickness (rear)
0.20
0.008
Maximum disc runout (front and rear)
Table 2-8. Brake Disc Specifications: XR 1200X
mm
in
SPECIFICATION
292
11.500
Diameter (front)
260
10.236
Diameter (rear)
4.75
0.187
Minimum thickness (front)
5.84
0.230
Minimum thickness (rear)
0.15
0.006
Maximum disc runout (front and rear)
2-10 2013 Sportster Service: Chassis
Wheels and Tires
Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
Table 2-9. Tubeless Cast Wheels: Tire Fitment
SPECIFIED TIRE
RIM SIZE
AND CONTOUR
WHEEL SIZE
AND POSITION
MODEL
SIZE
TYPE
120/70ZR18
Michelin Scorcher "11F"
T18 x 3.5 MT
18 in - front
XL 883L
150/60ZR17
Michelin Scorcher "11"
T17 x 4.5 MT
17 in - rear
100/90B19
Michelin Scorcher "31"
T19 x 2.15 MT
19 in - front
XL 883R
XL 883N
150/80B16
Michelin Scorcher "31"
T16 x 3.00 D
16 in - rear
XL 883R
XL 883N
130/90B16
Michelin Scorcher "31"
T16 x 3.00 MT
16 in - front
XL 1200C/C ANV
XL 1200CP/CA
150/80B16
Michelin Scorcher "31"
T16 x 3.00 MT
16 in - rear
120/70ZR18
Michelin Scorcher "11F"
E18 x 3.5 MT
18 in - front
XR 1200X
180/55ZR17
Michelin Scorcher "11"
E17 x 5.5 MT
17 in - rear
Table 2-10. Tube Type Steel Laced Wheels: Tire Fitment
SPECIFIED TIRE
TUBE SIZE
RIM SIZE
AND CONTOUR
WHEEL
MODEL
SIZE
TYPE
130/90B16
Michelin Scorcher "31"
MT90-16
T16 x 3.00 D
16 in - front
XL 1200X
150/80B16
Michelin Scorcher "31"
MT90-16
T16 x 3.00 D
16 in - rear
XL 1200X
MH90 21 M/C 54H WW
Dunlop D402F
MH90-21
T21 x 2.15 TLA
21 in - front
XL 1200V
150/80/B16 16 M/C 71H WWW
Dunlop D401
MT/MU90-16
T16 x 3.00 D
16 in - rear
130/90B16
Michelin Scorcher "31"
MT90-16
T16 x 3.00 D
16 in - front
XL 1200C/C
ANV/CP/CB
150/80B16
Michelin Scorcher "31"
MT90-16
T16 x 3.00 D
16 in - rear
2013 Sportster Service: Chassis 2-11
2.3
VEHICLE IDENTIFICATION NUMBER (VIN)
VEHICLE IDENTIFICATION NUMBER (VIN)
General
See
. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. Refer to
Location
See
. The full 17-digit VIN is stamped on the right
side of the frame near the steering head. In some destinations,
a printed VIN label is also attached to the right front downtube.
Abbreviated VIN
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.
1
2
om00848c
1. Stamped VIN
2. VIN label
Figure 2-1. VIN Locations: Sportster Models
1HD 4 CS 2 1 3 D C 111000
1
2
3
4
5
6
7
8
9
om00895e
Figure 2-2. Typical Harley-Davidson VIN: 2013 Sportster Models
Table 2-11. Harley-Davidson VIN Breakdown: 2013 Sportster Models
POSSIBLE VALUES
DESCRIPTION
POSITION
1HD=Originally manufactured for sale
within
the United States
World manufacturer identifier
1
5HD=Originally manufactured for sale
outside
of the United States
932=Originally manufactured in and for sale only in Brazil market
MEG=Originally manufactured in and for sale only in India market
1=Heavyweight motorcycle (901 cm
3
or larger)
Motorcycle type
2
4=Middleweight motorcycle (351 cm
3
to 900 cm
3
)
See VIN model table
Model
3
2=Evolution
®
883 cm
3
air-cooled, fuel-injected
Engine type
4
3=Evolution
®
1202 cm
3
air-cooled, fuel-injected
6=Evolution
®
1202 cm
3
precision-cooled, fuel-injected
2-12 2013 Sportster Service: Chassis
Table 2-11. Harley-Davidson VIN Breakdown: 2013 Sportster Models
POSSIBLE VALUES
DESCRIPTION
POSITION
Mid-year or Special Introduction
Normal Introduction
Introduction date/Configuration and
calibration recognition
5
2, 4=Domestic (DOM)
1=Domestic (DOM)
5, 6=California (CAL)
3=California (CAL)
B=Canada (CAN)
A=Canada (CAN)
D=HDI
C=HDI
F=Japan (JPN)
E=Japan (JPN)
H=Australia (AUS)
G=Australia (AUS)
K=Brazil (BRZ)
J=Brazil (BRZ)
M=Asia Pacific (APC)
L=Asia Pacific (APC)
P=India (IND)
N=India (IND)
Can be 0-9 or X
VIN check digit
6
D=2013
Model year
7
C=Kansas City, MO U.S.A.
Assembly plant
8
D=H-D Brazil-Manaus, Brazil (CKD)
N=Haryana India (Bawal District Rewari)
Varies
Sequential number
9
Table 2-12. VIN Model Codes: 2013 Sportster Models
NAME
MODEL
CODE
NAME
MODEL
CODE
Iron 883
™
XL 883N
LE
SuperLow
®
XL 883L
CR
Seventy-Two
™
XL 1200V
LF
883 Roadster
XL 883R
CS
1200 Custom
XL 1200CP
LH
1200 Custom
XL 1200C
CT
XL 1200C ANV
1200 Custom Limited A
XL 1200CA
LJ
Forty-Eight™
XL 1200X
LC
1200 Custom Limited B
XL 1200CB
LK
XR1200X™
XR 1200X
LD
2013 Sportster Service: Chassis 2-13
2.4
TIRES
REMOVAL
NOTE
Take care when removing and installing tire to prevent cosmetic
damage to wheel. This is especially true with wheels that fea-
ture painted surfaces.
1.
Remove wheel from motorcycle. See
or
.
2.
Deflate tire.
NOTE
Tube Type Wheels: do not completely remove tire from rim
to replace the tube only. Removing one side allows the tube
to be replaced and allows for inspection of tire.
3.
Loosen both tire beads from rim flange. Use a bead
breaker machine if available.
4.
Remove tire.
CLEANING, INSPECTION AND REPAIR
1.
Clean the inside of tire and outer surface of tube.
2.
If rim is dirty or rusty, clean with a stiff wire brush.
3.
Check wheels for lateral and radial runout before installing
a tire. See
2.7 CHECKING AND TRUING WHEELS
4.
Inspect the tire for wear and damage.
5.
Inspect tread depth. Replace worn tires.
6.
Replace tube and rim seal prior to installing tire.
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)
7.
Repair tread on tubeless tires if puncture is 1/4 in (6.4 mm)
or smaller. Repairs must be made from inside the tire.
8.
Always combine a patch and plug when repairing damaged
tires.
INSTALLATION
TORQUE VALUE
FASTENER
0.3-0.8 Nm
3-7
in-lbs
Valve stem, tube type, nut
1.4-1.7 Nm
12-15
in-lbs
Valve stem, tubeless type, nut
Mounting
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)
Mount tires with arrows molded into the tire sidewall with the
arrow pointing in the direction of forward rotation.
Locate the colored balance dot on the sidewall next to the valve
stem.
For tire pressures, see
1.8 TIRES AND WHEELS, Air Pressure
Tube Type Tires
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
NOTES
•
Replace the tube whenever the tire is replaced.
•
Only patch inner tubes as an emergency measure.
Replace a patched tube as soon as possible.
•
For correct tire and tube types, see
.
2-14 2013 Sportster Service: Chassis
1.
See
. On laced wheels, install a rim strip into
the rim well.
a.
Verify that the spokes do not protrude through the
nipples.
b.
Align the valve stem hole in rim strip with valve stem
hole in rim.
2.
Install tube and tire.
3.
Install valve stem nut. Tighten to 3-7
in-lbs
(0.3-0.8 Nm).
sm02466
Figure 2-3. Installing Rim Strip
Tubeless Tires
Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)
1.
See
. Replace damaged or leaking valve stems.
2.
XL 883L/N/R Cast Wheels:
a.
Install rubber grommet (5) on valve stem (1).
b.
Insert valve stem into rim hole.
c.
Install metal washer (4).
d.
Install nut (3). Tighten to 12-15
in-lbs
(1.4-1.7 Nm).
3.
XL 1200C/C ANV/CP/CA Cast Wheels:
Press the snap-
in valve stem (2) into the rim hole.
4.
Install tire.
4
2
5
3
1
sm07581
1. Bolt-on valve stem
2. Snap-in valve stem
3. Nut
4. Metal washer
5. Rubber grommet
Figure 2-4. Tubeless Tire Valve Stems
CHECKING TIRE RUNOUT
Lateral Runout
1.
Check tire pressure.
2.
See
. Turn the wheel on the axle and measure
tire lateral runout from a fixed point to a smooth area on
the tire sidewall. Avoid measuring on raised letters or
vents.
3.
Tire lateral runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds specification, remove tire from rim
and check rim lateral runout. See
.
a.
If rim lateral runout is within specification, the tire is
at fault and must be replaced.
b.
If rim lateral runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See
.
4.
Install the tire. Check tire lateral runout of replacement
tire.
2013 Sportster Service: Chassis 2-15
sm01803a
Figure 2-5. Tire Lateral Runout
Radial Runout
1.
Check tire pressure.
2.
See
. Turn the wheel on the axle and measure
tire radial runout at the tread centerline.
3.
Tire radial runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds this specification, remove tire from
rim and check rim radial runout.See
a.
If rim radial runout is within specification, the tire is at
fault and must be replaced.
b.
If rim radial runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See
4.
Install the tire. Check tire radial runout of replacement tire.
sm01804a
Figure 2-6. Tire Radial Runout
WHEEL BALANCING
NOTE
Install tire after balancing. See See
or
Static vs Dynamic
Wheel balancing is recommended to improve handling. Balan-
cing wheels reduces vibration especially at high speeds.
Static balancing will produce satisfactory results for normal
highway speeds. Dynamic balancing can produce better results
for deceleration.
Weights
The maximum weight permissible to accomplish balance is 3.5
oz (99.2 g) (total weight applied to the rim). If more than 3.5
oz (99.2 g) of weight is required, rotate the tire 180 degrees
on the rim and again balance the assembly. Balance wheels
to within 0.5 oz (14 g).
All wheel weights currently supplied by Harley-Davidson are
made from zinc which is lighter than lead. The weight of each
zinc segment is 0.18 oz (5 g) as compared to 0.25 oz (7 g) for
lead. Weights are stamped for easy identification.
NOTES
•
If adding more than 1.5 oz (43 g) of weight at one location,
divide the amount so that half is applied to each side of
rim.
•
On cast wheels without a flat area near the bead, place
the weights crosswise through the opening.
1.
See
. Place weights on a smooth surface of the
wheel rim such that centrifugal force will help keep them
in place. Make sure the area of application is completely
clean, dry, and free of oil and grease.
NOTE
See
. When installing wheel weights, consider cos-
metics. Keep snaking (1) within 0.040 in (1.02 mm) (2) of
straight. Also keep the angle alignment of individual segments
(3) within 3 degrees.
2.
Remove paper backing from the weight. Press firmly in
place and hold for ten seconds.
3
2
1
sm07192b
1. Snaking
2. Not to exceed 0.040 in (1.02 mm)
3. Not to exceed 3 degree
Figure 2-7. Weight Segment Alignment
2-16 2013 Sportster Service: Chassis
1
2
sm07191b
1. Laced steel
2. Cast
Figure 2-8. Wheel Weight Placement
2013 Sportster Service: Chassis 2-17
2.5
WHEELS
GENERAL
TORQUE VALUE
FASTENER
81-88 Nm
60-65 ft-lbs
Axle, front, nut
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
Good handling and maximum tire mileage are directly related
to the care of wheels and tires. Regularly inspect wheels and
tires for damage and wear. If handling problems occur, see
or refer to
for a list of
probable causes.
Keep tires inflated to the recommended air pressure. Always
balance the wheel after replacing a tube or tire.
Table 2-13. Wheel Service Chart
REMEDY
CHECK FOR
Tighten front axle nut to 60-65 ft-lbs (81-88 Nm).
Loose axle nuts.
Tighten rear axle nut to 95-105 ft-lbs (129-142 Nm).
Replace wheel hub bearings. See
Excessive side-play or radial (up-and-down) play in wheel hubs.
Tighten or replace spokes. See
and
2.7 CHECKING AND TRUING WHEELS
Loose spokes.
Check rear wheel alignment as described in this section or repair
rear fork as described in
Alignment of rear wheel in frame or with front wheel.
True wheels, replace rims or replace spokes. See
and
2.7 CHECKING AND TRUING WHEELS
Rims and tires lateral runout more than 1/32 in (0.76 mm).
Rims and tires vertical runout not be more than 1/32 in (0.76
mm).
Replace as described in
and
.
Irregular or peaked front tire wear.
Inflate tires to correct pressure. See
Correct tire inflation.
Static balance may be satisfactory if dynamic balancing facilities
are not available. However, dynamic balancing is strongly
recommended.
Correct tire and wheel balance.
Replace pitted or worn bearings. Adjust fall-away. See
2.21 FORK STEM AND BRACKET ASSEMBLY
.
Steering head bearings.
Check for leaks. See
or
.
Damper tubes.
Check damping action and mounting stud bushings. See
.
Shock absorbers.
Check for looseness. See
Rear fork bearings.
WHEEL BEARING END PLAY
1.
Raise the wheel off the ground.
2.
See
. Mount a magnetic base dial indicator on
the brake disc.
3.
Set the indicator contact point on the end of the axle.
4.
Move the wheel back as far as it will go. Hold the wheel
in position and zero the dial indicator.
5.
Move the wheel forward as far as it will go. Note the
reading of the dial indicator. Verify the reading.
6.
If end play is greater than specification, remove the wheel
and replace both wheel bearings. Refer to
2-18 2013 Sportster Service: Chassis
3
4
2
1
sm01778
1. Magnetic base
2. Brake disc
3. Axle
4. Dial indicator
Figure 2-9. Check Wheel Bearing End Play
Table 2-14. Wheel Bearing End Play
mm
in
DIRECTION
0.05
0.002
Lateral
FRONT WHEEL
TORQUE VALUE
FASTENER
21.7-32.6 Nm
16-24 ft-lbs
Hub plate mounting screw
21.7-32.6 Nm
16-24 ft-lbs
Brake disc, front, screw
21.7-32.6 Nm
16-24 ft-lbs
Brake disc, front, screw
21.7-32.6 Nm
16-24 ft-lbs
Brake disc, front, screw
21.7-32.6 Nm
16-24 ft-lbs
Brake disc, front, screw
81-88 Nm
60-65 ft-lbs
Axle, front, nut
28.5-36.6 Nm
21-27 ft-lbs
Axle, front, pinch screw: XL
Models
55.6-65.1 Nm
41-48 ft-lbs
Axle, front, pinch screw: XR
1200X
Removal
1.
Raise the front wheel off the ground.
NOTES
•
Do not operate the front brake lever with the front wheel
removed or the caliper pistons may be forced out. Seating
the pistons requires disassembly of the caliper.
•
On models with dual disc brakes, remove both calipers.
2.
See
. Remove brake caliper mounting screws
(3). Slide caliper (4) off brake disc and secure caliper out
of the way.
3.
XL 1200X/C/C ANV/CP/CA/CB:
Remove the front fender.
See
4.
Remove axle nut (1) and flat washer (2) from axle on left
side of vehicle.
5.
See
. On right side of vehicle, loosen nut (4)
on pinch screw (1). Pull axle out of hub while supporting
wheel.
6.
Remove spacer and front wheel assembly.
2
1
4
3
sm07127
1. Axle nut
2. Flat washer
3. Brake caliper mounting screws
4. Brake caliper
Figure 2-10. Left Side Front Wheel Mounting
3
4
1
5
2
sm07126
1. Pinch screw
2. Washer
3. Lockwasher
4. Nut
5. Axle
Figure 2-11. Right Side Front Wheel Mounting
Disassembly: Cast Front Wheel
1.
If necessary, remove tire. See
2.
Remove five screws and left side brake disc.
2013 Sportster Service: Chassis 2-19
3.
If necessary, remove five screws and right side brake disc
(dual front disc models) or hub plate (single front disc
models).
4.
If necessary, remove roller bearings and hub spacer. See
2.5 WHEELS, Sealed Wheel Bearings
.
Assembly Cast Single Disc
Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)
1.
See
. Install hub spacer (7) and
new
wheel
bearings (6). See
2.5 WHEELS, Sealed Wheel Bearings
.
2.
XL 883N:
Install hub plate (8) on right side of wheel.
Secure with
new
screws and tighten in an alternating
pattern to 16-24 ft-lbs (21.7-32.6 Nm).
NOTE
See
. Orient brake discs with the word LEFT (1)
facing out. Verify that the bulb shaped end (2) of the slots points
opposite the direction of rotation (3).
3.
Install brake disc. Secure with
new
screws and tighten in
an alternating pattern to 16-24 ft-lbs (21.7-32.6 Nm).
3
7
6
2
9
13
6
8
5
1
9
10
12
11
4
sm07574
1. Axle
2. Nut
3. Washer
4. Wide spacer
5. Narrow spacer
6. Bearings (2)
7. Hub spacer
8. Hub plate: XL 883N
9. Fastener (10)
10. Brake disc
11. XL 883N
12. XL 883L
13. XL 1200C/C ANV/CP/CA
Figure 2-12. Single Disc Wheels: XL Models
2-20 2013 Sportster Service: Chassis
2
3
1
sm07576
1. Left
2. Slot bulb end
3. Direction of rotation
Figure 2-13. Single Disc Orientation
Assembly Cast Dual Disc: XL 883R
1.
See
. Install hub spacer (7) and
new
wheel
bearings (6). See
2.5 WHEELS, Sealed Wheel Bearings
.
NOTE
See
. The words LEFT (1) and RIGHT (2) on the
discs will be located on the left and right sides.
2.
Hold brake discs together with inboard sides facing each
other (minimum thickness and part number stampings are
on outboard side of brake disc). The bulb shaped end (3)
of each slot is on the trailing edge of the slot in the direc-
tion of rotation (4).
3.
Rotate one brake disc as necessary, until all vent holes
are aligned with those of the other brake disc.
4.
Keeping the paint marks on the edge of both discs aligned,
install both brake discs onto hub. Secure with
new
screws.
5.
Holding brake discs aligned, use a felt marking pen or
paint pen to draw a line across the edge of both brake
discs.
6.
Tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6
Nm).
7.
Verify that wheel is true. See
TRUING WHEELS, Cast Wheel Runout
.
8
6
4
5
1
2
7
6
3
8
9
9
sm07573
1. Axle
2. Nut
3. Washer
4. Wide spacer
5. Narrow spacer
6. Bearing (2)
7. Hub spacer
8. Fastener (10)
9. Brake disc (2)
Figure 2-14. Dual Disc Wheel: XL 883R
3
1
4
2
sm07570
1. Left
2. Right
3. Slot bulb end
4. Direction of rotation
Figure 2-15. Dual Disc Orientation: XL 883R
2013 Sportster Service: Chassis 2-21
Assembly Cast Dual Disc: XR 1200X
See
. . XR 1200X models are equipped with a
floating front brake disc. They are non-directional and do not
need to be matched with opposite disc.
Tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6 Nm).
7
5
4
4
6
1
3
2
7
5
8
8
sm07572
1. Axle
2. Nut
3. Washer
4. Spacer (2)
5. Bearing (2)
6. Hub spacer
7. Fastener (10)
8. Brake disc (2)
Figure 2-16. Dual Disc Wheel: XR 1200X
Disassembly: Laced Front Wheel
1.
See
. If necessary, remove five screws (1) and
brake disc (9).
2.
If necessary, remove wheel bearings (4) and hub spacer
(6). See
2.5 WHEELS, Sealed Wheel Bearings
.
NOTE
If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels. See
and
2.7 CHECKING AND TRUING WHEELS
3.
If it is necessary to disassemble wheel, loosen spoke
nipples and spokes and slide each spoke out of hub.
Assembly: Laced Front Wheel
1.
See
. Install hub spacer (6) and
new
wheel
bearings (4) if removed. See
2.
If hub and rim were disassembled, reassemble and true
wheel. See
and
Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)
3.
Install brake disc (9). Secure with
new
screws (1) and
tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6
Nm).
4.
Verify that wheel is true.
11
10
4
9
3
6
4
5
8
1
2
7
sm01777g
1. Screw
2. Washer
3. Nut
4. Roller bearing
5. Bearing spacer, narrow
6. Hub spacer
7. Bearing spacer, wide
8. Front axle
9. Brake disc
10. Wheel: 16 in XL 1200X/CP/CB certain markets
11. Wheel: 21 in XL 1200V
Figure 2-17. Laced Front Wheel
Installation
1.
Apply a light coat of ANTI-SEIZE LUBRICANT to the axle,
bearing bores, and hub spacer bore.
2.
Position wheel between forks. Verify that bearing spacers
on right and left side of wheel bearings are in position.
2-22 2013 Sportster Service: Chassis
3.
With pinch screw loose, insert threaded end of axle
through right side fork. Push axle through fork and wheel
hub until it begins to emerge from left side of hub.
4.
Push axle through left fork, until axle shoulder contacts
external bearing spacer on right fork side.
5.
Install flat washer and axle nut over threaded end of axle.
Insert screwdriver or steel rod through hole in axle on right
side of vehicle. While holding axle stationary, tighten axle
nut to 60-65 ft-lbs (81-88 Nm).
6.
Dual Disc Models:
Align calipers to brake discs:
a.
Make sure axle pinch screw nut is loose.
b.
Position right fork leg against bearing spacer.
c.
XL Models:
Tighten axle pinch screw to 21-27 ft-lbs
(28.5-36.6 Nm).
d.
XR 1200X:
Tighten axle pinch screw to 41-48 ft-lbs
(55.6-65.1 Nm).
7.
XL 1200X/C/C ANV/CP/CA/CB:
Install front fender. See
.
8.
Install brake caliper(s). See
or
Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling and can cause loss of control, which
could result in death or serious injury. (00285b)
Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury. (00284a)
9.
Pump brake lever to move pistons out until they contact
outside brake pad(s). Verify piston location against pad.
REAR WHEEL
TORQUE VALUE
FASTENER
40.7-61.1 Nm
30-45 ft-lbs
Brake disc, rear, screw
81.3 Nm
60 ft-lbs
Sprocket mounting screw, 1st
torque
108.0 Nm
80 ft-lbs
Sprocket mounting screw, final
torque
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
Removal
1.
Secure motorcycle upright on a suitable lift. Raise rear
end of motorcycle high enough to permit wheel removal.
2.
XL Models:
Remove rear muffler. See
3.
XL Models:
Remove right lower shock absorber nut and
pull screw out slightly. This will help avoid damage to
sprocket when rear wheel is removed.
4.
See
. Remove E-clip (2), axle nut (1) and
washer (3).
5.
Loosen adjuster screws several turns to relieve belt ten-
sion.
6.
Gently tap end of axle (4) with a soft hammer to loosen.
Pull axle free of rear fork assembly.
7.
Slide wheel forward and slip belt off sprocket.
NOTE
It is not necessary to disassemble rear brake caliper in order
to remove rear wheel.
8.
XR 1200X:
Disengage brake hose from clamps on lower
side of rear fork. Carefully slide caliper and bracket
assembly forward to disengage from brake disk and boss
on rear fork. Support assembly from frame using rope or
bungee cord.
9.
Remove spacers and roll rear wheel assembly back out
of fork.
10. Remove rear wheel assembly.
NOTE
Do not operate rear brake pedal with rear wheel removed or
caliper piston may be forced out of piston bore. Seating piston
requires disassembly of caliper.
4
3
1
2
sm03593b
1. Axle nut
2. E-clip
3. Washer
4. Rear axle
Figure 2-18. Rear Wheel Mounting
Disassembly
NOTES
•
Sportster models sold in certain markets are equipped
with rear wheel compensating sprockets. See
•
Mark parts to indicate location. Do not mix parts upon
assembly.
1.
If necessary, remove tire. See
2013 Sportster Service: Chassis 2-23
2.
See
or
. If necessary, remove
screws to detach rear brake disc from left side of wheel.
3.
If necessary, remove screws and washers to detach rear
sprocket from right side of wheel.
4.
If necessary, remove wheel bearings and hub spacer. See
2.5 WHEELS, Sealed Wheel Bearings
.
NOTE
Laced Wheel: If only rim is to be replaced, tape spokes
together to hold position on hub and remove spokes from rim.
See
.
5.
Laced Wheel:
If it is necessary to disassemble wheel,
loosen the spoke nipples and spokes and slide each spoke
out of hub.
Cleaning and Inspection
1.
Inspect all parts for damage or excessive wear.
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
2.
Inspect brake pads and disc. See
OR
3.
Inspect rear belt and sprocket. See
Assembly
1.
Laced Wheel:
if wheel was disassembled, reassemble
hub, rim, spokes and nipples, and tighten spokes. See
.
2.
Install hub spacer and
new
wheel bearings, if removed.
See
2.5 WHEELS, Sealed Wheel Bearings
.
a.
Cast or disc wheel:
See
b.
Laced wheel:
See
3.
If brake disc was removed, install brake disc on valve stem
side of wheel. Secure with
new
screws and tighten to 30-
45 ft-lbs (40.7-61.1 Nm).
NOTE
Sportster models sold in certain markets are equipped with
rear wheel compensating sprockets. See
4.
If rear sprocket was removed, install sprocket on side of
wheel opposite valve stem.
a.
Secure with
new
screws and washers. Tighten to 60
ft-lbs (81.3 Nm).
b.
Loosen each screw 180 degrees and tighten to 80 ft-
lbs (108.0 Nm).
5.
Verify that wheel assembly is true. See
.
6.
Install tire. See
8
11
4
2
17
6
9
14
15
12
5
6
16
1
3
7
13
10
sm07577
1. E-clip
2. Screw (5)
3. Washer
4. Washer (5)
5. Axle nut
6. Roller bearing (2)
7. Sprocket
8. Spacer, wide
9. Spacer, narrow
10. Brake disc
11. Axle
12. Hub spacer
13. Screw (5)
14. Wheel: 16 in XL 1200C/C ANV/CP/CA (certain
markets)
15. Wheel: 16 in XL 883N/R
16. Wheel: 17 in XL 883L
17. Wheel: 17 in XR 1200X
Figure 2-19. Cast Rear Wheel
2-24 2013 Sportster Service: Chassis
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