Harley Davidson 2013 Sportster Models. Service Manual — page 3

Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could
result in death or serious injury. (00010a)

Perform necessary set-up tasks before customer delivery. See
applicable model year predelivery and set-up instructions.

The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions sys-
tems operation. See

1.5 MAINTENANCE SCHEDULE

SAFE OPERATING MAINTENANCE

NOTES

•

Do not attempt to tighten engine head bolts or engine
damage may result.

•

During the initial break-in period, use only GENUINE
HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL
20W50. Failure to use the recommended oil will result in
improper break-in of the engine cylinders and piston rings.

Inspect motorcycle on a regular basis for additional mainten-
ance needs. Routinely check components between regular
maintenance intervals. Always inspect motorcycle after periods
of storage before riding.

Check:

Tires for correct pressure, excessive wear or any signs of
tire damage.

Drive belt tension and condition.

Brakes, steering and throttle for responsiveness.

Brake fluid level and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and discs for wear.

Cables for fraying, crimping and free operation.

Engine oil and transmission fluid levels.

Headlamp, auxiliary/fog lamp, tail lamp, stop lamp, horn
and turn signal operation.

SHOP PRACTICES

Repair Notes

General maintenance practices are given in this section.

NOTES

•

Repair = Disassembly/Assembly.

•

Replacement = Substitute a new part for existing com-
ponent.

All special tools and torque values are noted at the point of
use.

All required parts or materials can be found in the parts catalog.

Safety

Safety is always the most important consideration when per-
forming any job.

•

Always have a complete understanding of the task.

•

Use common sense.

•

Use the proper tools.

•

Protect yourself and bystanders with approved eye protec-
tion.

Don't just do the job, do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. If a hoist
and adjustable lifting beam or sling are needed to remove some
parts, verify that:

•

The lengths of multiple chains or cables from the hoist to
the part are equal and parallel.

•

Slings, chains and cables are positioned directly over the
center of the part.

•

No obstructions will interfere with the lifting operation.

•

Parts are not left suspended.

Be sure to check capacity rating and condition of hoists,
slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition
can lead to an accident, which could result in death or
serious injury. (00466c)

Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Verify that
no parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part
to verify proper installation.

Cleaning

Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris. Clean and inspect all parts as they are removed. Verify
all holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other material.
Verify the part is clean when installed.

Thoroughly clean all parts to be reused before assembly. Clean
parts promote better component operation and longer life.
Seals, filters and covers used in this vehicle keep out
extraneous dirt and dust. Keep these items in good condition
to guarantee satisfactory operation.

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2013 Sportster Service: Maintenance 1-3

When instructed to clean fastener threads or threaded holes,
always:

•

Clean all threadlocking material from fastener threads and
threaded holes.

•

Use a wire brush to clean fastener threads.

•

Use a thread chaser or other suitable tool to clean
threaded holes.

•

Use PJ1 cleaner or equivalent to remove all traces of oil
and contaminants from threads.

•

Clear all threaded holes with low pressure compressed
air.

Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
castings to crack or break.

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Make all necessary
adjustments. Inspect your work when finished to verify that
everything is done.

Operate the vehicle to perform any final check or adjustments.
If all is correct, the vehicle is ready to go back to the customer.

Checking Torques on Fasteners

Check torque using a torque wrench set to the minimum spe-
cification for that fastener. If the fastener does not rotate, the
torque has been maintained. If the fastener rotates, remove it
to determine if it has a threadlocking agent.

If it has a threadlocking agent, clean all material from the
threaded hole. Replace the fastener with a

new

one or clean

the original fastener threads and apply the appropriate
threadlocking product. Install and tighten the fastener to spe-
cification.

If the fastener does not use a threadlocking agent, install and
tighten it to specification.

Magnetic Parts Trays

Magnetic parts trays are common in the service facility because
they are convenient and can keep parts from becoming lost
during a repair procedure. However, hardened steel parts can
become magnetized when held in magnetic parts trays.

Metal fragments from normal wear are usually trapped in the
oil filter or by the magnetic drain plug. Magnetized parts in the
engine can retain these fragments, potentially causing acceler-
ated engine wear and damage.

Never place parts that will be returned to service inside the
vehicle's powertrain such as gears, thrust washers and espe-
cially bearings in magnetic parts trays.

REPAIR AND REPLACEMENT
PROCEDURES

Hardware and Threaded Parts

Install thread repair inserts when threaded holes in castings
are stripped, damaged or not capable of withstanding specified
torque.

Replace bolts, nuts, studs, washers, spacers and small
common hardware if missing or damaged. Clean up or repair
minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication fittings.

Use LOCTITE 565 THREAD SEALANT on pipe fitting threads.

Threadlocking Agents

Always follow specific service manual procedures when working
with fasteners containing preapplied threadlocking agents when
fastener replacement is recommended. When re-using
fasteners containing threadlocking agents, thoroughly clean
all fasteners and threaded holes. Always use the recommended
threadlocking agent for the specific procedure.

Wiring, Hoses and Lines

Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.

Instruments and Gauges

Replace damaged or defective instruments and gauges.

Bearings

Always use the proper tools and fixtures when servicing bear-
ings.

Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.

When bearings are installed against shoulders, always verify
that the chamfered side of the bearing faces the shoulder.
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part. Install
bearings with numbered side facing out.

Only remove bearings if necessary. Removal usually damages
bearings requiring replacement with

new

parts.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings requiring replacement.

When pressing or driving bushings, always apply pressure in
line with the bushing bore. Use a bearing/bushing driver or a
bar with a smooth, flat end. Never use a hammer to drive
bushings.

Verify that all oil holes are properly aligned during installation.

Gaskets

Always discard gaskets after removal. Replace with

new

gas-

kets. Never use the same gasket twice. Verify that gasket holes
match up with holes in the mating part. Be aware that sections
of a gasket may be used to seal passages.

Lip-Type Seals

Lip seals are used to seal oil or grease and are usually installed
with the sealing lip facing the contained lubricant. Seal orient-
ation, however, may vary under different applications.

Do not remove seals unless necessary. Only remove seals to
gain access to other parts or if seal damage or wear dictates
replacement.

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1-4 2013 Sportster Service: Maintenance

Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal
twice.

O-Rings

Always discard O-rings after removal. Many O-rings are similar
in size and appearance. Always use

new

O-rings keeping them

packaged until use to avoid confusion. To prevent leaks, lub-
ricate the O-rings before installation with the same type of
lubricant as that being sealed. Be sure that all gasket, O-ring
and seal mating surfaces are thoroughly clean before installa-
tion.

Gears

Always check gears for damaged or worn teeth.

Remove burrs and rough spots with a honing stone or crocus
cloth before installation.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force to remove.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Verify that tapered splines are clean, dry
and free of burrs before putting them in place. Press mating
parts together tightly.

Clean all rust from the machined surfaces of

new

parts.

Part Replacement

Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)

Always install

new

genuine Harley-Davidson parts and

accessories. This will provide best service life and maintain
compliance with noise and emissions regulations.

Installing non-Harley-Davidson, off-road or competition parts
can void warranty or result in an unsafe vehicle.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease-
proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Bearings

Wash bearings in a non-flammable petroleum cleaning solution.
Never use a solution that contains chlorine. Knock out packed
lubricant by tapping the bearing against a wooden block. Wash
bearings again.

Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)

Cover bearings with a clean shop towel and allow to air dry.
Do not spin bearings while they are drying. Never use com-
pressed air to dry bearings.

When dry, coat bearings with clean oil. Wrap bearings in clean
paper.

TOOL SAFETY

Air Tools

•

Always use approved eye protection equipment when
performing any task using air-operated tools.

•

On all power tools, use only recommended accessories
with proper capacity ratings.

•

Do not exceed air pressure ratings of any power tools.

•

Bits should be placed against work surface before air
hammers are operated.

•

Disconnect the air supply line to an air hammer before
attaching a bit.

•

Never point an air tool at yourself or another person.

•

Protect bystanders with approved eye protection.

Wrenches

•

Never use an extension on a wrench handle.

•

If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something suddenly
releases.

•

Always keep the wrench squarely installed on the fastener.

•

Never use a hammer on any wrench other than a
STRIKING FACE wrench.

•

Discard any wrench with damaged or battered points.

•

Never use a pipe wrench to bend, raise or lift a pipe.

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2013 Sportster Service: Maintenance 1-5

Pliers/Cutters/Pry Bars

•

Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use them on live electrical cir-
cuits.

•

Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.

•

Always cut at right angles.

•

Do not use any pry bar as a chisel, punch or hammer.

Hammers

•

Never strike a hammer against a hardened object, such
as another hammer.

•

Always grasp a hammer handle firmly, close to the end.

•

Strike the object with the full face of the hammer.

•

Never work with a hammer which has a loose head or
cracked handle.

•

Discard hammer if face is chipped or mushroomed.

•

Wear approved eye protection when using striking tools.

•

Protect bystanders with approved eye protection.

Punches/Chisels

•

Never use a punch or chisel with a chipped or mush-
roomed end. Dress mushroomed chisels and punches
with a grinder.

•

Hold a chisel or a punch with a tool holder if possible.

•

When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.

•

Always wear approved eye protection when using these
tools.

•

Protect bystanders with approved eye protection.

Screwdrivers

•

Do not use a screwdriver for prying, punching, chiseling,
scoring or scraping.

•

Use the right type of screwdriver for the job. Match the tip
of a screwdriver to the fastener.

•

Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers.

•

Screwdriver handles are not intended to act as insulation.
Do not use them on live electrical circuits.

•

Do not use a screwdriver with rounded edges because it
will slip. Redress with a grinder.

Ratchets and Handles

•

Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually. Ratchets
should be rebuilt with the entire contents of service kit.

•

Never hammer on a ratchet or put a pipe extension on a
ratchet handle for added leverage.

•

Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.

•

When breaking a fastener loose, apply a small amount of
pressure as a test to be sure the ratchet's gear wheel is
engaged with the pawl.

Sockets

•

Never use hand sockets on power or impact wrenches.
Select only impact sockets for use with air or electric
impact wrenches.

•

Select the right size socket for the job.

•

Always keep the wrench or socket squarely on the
fastener.

•

Replace sockets showing cracks or wear.

•

Keep sockets clean.

•

Always use approved eye protection when using power
or impact sockets.

Storage Units

•

Do not open more than one loaded drawer at a time. Close
each drawer before opening another to prevent the cabinet
from unexpectedly tipping over.

•

Close lids and lock drawers and doors before moving
storage units.

•

Do not pull on a tool cabinet. Always push tool cabinets
in front of you.

•

Set the brakes on the locking casters after the cabinet has
been rolled into position.

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1-6 2013 Sportster Service: Maintenance

1.3

FUEL AND OIL

FUEL

Always use a good quality unleaded gasoline. Octane ratings
are usually found on the pump. Refer to

Table 1-1

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur-
ization a possibility.

Table 1-1. Octane Ratings

RATING

SPECIFICATION

91 (95 RON)

Pump Octane (R+M)/2

GASOLINE BLENDS

Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasoline is
blended with alcohol and/or ether to create oxygenated blends.
The type and amount of alcohol or ether added to the fuel is
important.

Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)

•

Gasoline/METHYL TERTIARY BUTYL ETHER (MTBE)
blends are a mixture of gasoline and as much as 15%
MTBE. Gasoline/MTBE blends use in your motorcycle is
approved.

•

ETHANOL fuel is a mixture of ethanol (grain alcohol) and
unleaded gasoline and can have an impact on fuel
mileage. Fuels with an ethanol content of up to 10% may
be used in your motorcycle without affecting vehicle per-
formance. U.S. EPA regulations currently indicate that
fuels with 15% ethanol (E15) are restricted from use in
motorcycles at the time of this publication. Some motor-
cycles are calibrated to operate with higher ethanol con-
centrations to meet the fuel standards in certain countries.

•

REFORMULATED OR OXYGENATED GASOLINES
(RFG) describes gasoline blends that are specifically

designed to burn cleaner than other types of gasoline.
This results in fewer tailpipe emissions. They are also
formulated to evaporate less when filling the tank. Refor-
mulated gasolines use additives to oxygenate the gas.
Your motorcycle will run normally using this type of fuel.
Harley-Davidson recommends using it whenever possible
as an aid to cleaner air in our environment.

•

Do not use racing fuel or fuel containing methanol. Use
of these fuels will damage the fuel system.

•

The only octane booster Harley-Davidson recommends
is SCREAMIN' EAGLE SUPER OCTANE BOOST (avail-
able only in the U.S.). This is the only octane booster that
has been extensively tested and approved for use with
Harley-Davidson engines and components.

Some gasoline blends might adversely affect starting, driveab-
ility or fuel efficiency. If any of these problems are experienced,
try a different brand of gasoline or gasoline with a higher octane
blend.

ENGINE LUBRICATION

Prolonged or repeated contact with used motor oil may
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b)

If swallowed, do not induce vomiting. Contact a physician
immediately. In case of contact with eyes, immediately
flush with water. Contact a physician if irritation persists.
(00357c)

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life
of the engine. Always use the proper grade of oil for the lowest
temperature expected before the next scheduled oil change.
Refer to

Table 1-2

This motorcycle was originally equipped with GENUINE
HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50.
H-D 360 is the preferred oil under normal operating conditions.
If operation under extreme cold or heat are expected, refer to

Table 1-2

for alternative choices.

If necessary and H-D 360 is not available, add oil certified for
diesel engines. Acceptable designations include: CH-4, CI-4
and CJ-4. The preferred viscosities, in descending order are:
20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

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2013 Sportster Service: Maintenance 1-7

Table 1-2. Recommended Engine Oils

COLD WEATHER

STARTS BELOW

50 °F (10 °C)

LOWEST AMBIENT

TEMPERATURE

RATING

VISCOSITY

TYPE

Excellent

Above 30 °F (-1 °C)

HD 360

SAE 20W50

Screamin' Eagle SYN 3 Full Synthetic
Motorcycle Lubricant

Good

Above 40 °F (4 °C)

HD 360

SAE 20W50

Genuine Harley-Davidson H-D 360
Motorcycle Oil

Poor

Above 60 °F (16 °C)

HD 360

SAE 50

Genuine Harley-Davidson H-D 360
Motorcycle Oil

Poor

Above 80 °F (27 °C)

HD 360

SAE 60

Genuine Harley-Davidson H-D 360
Motorcycle Oil

Excellent

Below 40 °F (4 °C)

HD 360

SAE 10W40

Genuine Harley-Davidson H-D 360
Motorcycle Oil

WINTER LUBRICATION

Change engine oil often in colder climates. If motorcycle is
frequently used for trips less than 15 mi (24 km), in ambient
temperatures below 60 °F (16 °C), reduce oil change intervals
to 1500 mi (2400 km).

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some water vapor

condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice.
Over time, accumulated slush or ice may block the oil lines
and cause engine damage.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and not allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

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1-8 2013 Sportster Service: Maintenance

1.4

BULB REQUIREMENTS

BULB CHART

Table 1-3. Bulb Chart

HARLEY-DAVIDSON

PART NUMBER

CURRENT

DRAW

(AMPERAGE)

BULBS

REQUIRED

DESCRIPTION
(ALL LAMPS 12 V)

LAMP

68329-03

5.0/4.58

High beam/low beam

Headlamp

53436-97

0.32

Position lamp international

LED assembly

All models***

Indicator lamp module

LED assembly

XL 883N, XL 1200X/V (Domestic)***

License plate lamp

52441-95

0.35

XL 883N, XL 1200X/V (HDI)

LED assembly

Tail and stop lamp

XL 1200C/C ANV/CP/CA/CB***

68167-04

2.10/0.59

Tail and stop lamp (all other models)

68168-89A

2.25/0.59

Front/running

Turn signal lamp

68163-84

1.75

Front international

68168-89A

2.25

Rear (Domestic XL 883N, XL 1200X/V)**

68572-64B

2.25

Rear (Canada XL 883N, XL 1200X)

LED assembly

Rear (HDI XL 883R, XL 1200X/V)***

68163-84

1.75

Rear (all other models)

* XL 1200C/C ANV/CP/CA/CB tail and stop lamp is illuminated with LED's. Replace entire assembly upon failure.
** Functions as turn signal, tail and stop lamps.
*** This is an LED assembly. Replace entire assembly upon failure.

HOME

2013 Sportster Service: Maintenance 1-9

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