Harley Davidson 2013 Sportster Models. Service Manual — page 6
1
2
3
4
5
sm04938
1. Air box assembly
2. Air filter cover
3. Active intake connector [178] (if equipped)
4. Wiring harness
5. Recess
Figure 1-15. Installing Air Filter Cover
CLEANING FILTER ELEMENT
Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)
NOTE
Do not tap the filter on a hard surface.
1.
Wash the filter in warm soapy water.
2.
To remove soot, soak the filter in warm soapy water for
30 minutes.
NOTE
The filter is clean if light is visible through filter.
3.
Hold the filter up to light.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
4.
Dry the filter with low-pressure compressed air from the
inside.
1-22 2013 Sportster Service: Maintenance
1.8
TIRES AND WHEELS
AIR PRESSURE
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)
Always maintain proper tire pressure as specified in
.
Do not load tires beyond GAWR specified in
.
Underinflated, over-inflated or overloaded tires can fail.
Check tire pressure when the tires are cold. Refer to
.
NOTE
Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.
Table 1-7. Air Pressure (cold): 2013 Sportster Models
kPa
psi
WHEEL
MODEL
248
36
Front
XL 883L
290
42
Rear
207
30
Front
XL 883N
276
40
Rear
207
30
Front
XL 883R
276
40
Rear
248
36
Front
XL 1200C/C ANV
276
40
Rear
248
36
Front
XL 1200CP
276
40
Rear
248
36
Front
XL 1200CA
276
40
Rear
248
36
Front
XL 1200CB
276
40
Rear
207
30
Front
XL 1200V
276
40
Rear
248
36
Front
XL 1200X
276
40
Rear
248
36
Front
XR 1200X
290
42
Rear
TIRE REPLACEMENT
Tread Wear
Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)
Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in (0.8 mm) tread depth
remains, the tire can:
•
Be more easily damaged leading to tire failure.
•
Provide reduced traction.
•
Adversely affect stability and handling.
Replace the tires with
new
tires before the tread wear bars
appear:
•
See
or
. Indicators (1) on the tire
sidewalls point to tread wear bars (2) in the tread.
•
Tread wear bars appear in the tread pattern when 1/32 in
(0.8 mm) or less of tread remains.
2
1
sm07185d
1. Indicator
2. Tread wear bar
Figure 1-16. Tread Pattern: Michelin Tires
2013 Sportster Service: Maintenance 1-23
1
2
sm07439a
1. Indicator
2. Tread wear bar
Figure 1-17. Tread Pattern: Dunlop Tires
Tire Damage
Replace tires with
new
tires when:
•
Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.
•
A bump, bulge or split is found anywhere on the tire.
•
A puncture, cut or other damage cannot be repaired.
SPECIFIED 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)
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)
•
Store
new
tires on a horizontal tire rack. Do not stack tires
in a vertical stack.
•
Mount only Harley-Davidson specified tires. Refer to
.
Table 1-8. Specified Tires: 2013 Sportster Models
SPECIFIED TIRE
WHEEL
MODEL
Michelin Scorcher "11F" 120/70ZR18
F
XL 883L
Michelin Scorcher "11" 150/60ZR17
R
Michelin Scorcher "31" 100/90B19
F
XL 883N/R
Michelin Scorcher "31" 150/80B16
R
Michelin Scorcher "31" 130/90B16
F
XL 1200C/X
XL 1200C
ANV
XL 1200CP
XL 1200CA
XL 1200CB
Michelin Scorcher "31" 150/80B16
R
Dunlop D402F MH90 21 M/C 54H WW
F
XL 1200V
Dunlop D401 150/80B16 M/C 71H
WWW
R
Michelin Scorcher "11F" 120/70ZR18
F
XR 1200X
Michelin Scorcher "11" 180/55ZR17
R
WHEEL BEARINGS
NOTE
Replace bearings in sets only. See
.
1.
Replace when bearings exceed end play service wear
limit of 0.002 in (0.051 mm).
2.
Inspect any time the wheels are removed.
a.
Inspect the play of the wheel bearings by finger while
they are in the wheel.
b.
Rotate the inner bearing race. Listen for abnormal
noise.
c.
Verify smooth bearing rotation.
3.
Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings.
WHEEL SPOKES
TOOL NAME
PART NUMBER
SPOKE TORQUE WRENCH
HD-48985
SPOKE NIPPLE WRENCH
HD-94681-80
TORQUE VALUE
FASTENER
6.2 Nm
55
in-lbs
Spoke nipple
Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)
1-24 2013 Sportster Service: Maintenance
Do not over tighten spoke nipples. Protruding spoke
nipples can damage rim seal, resulting in rapid tire defla-
tion, which could cause death or serious injury. (00611b)
When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)
Identify Wheel Spoke Groups
NOTE
Spokes are grouped in sets of four.
1.
Raise wheel with a suitable lifting device.
2.
See
. Starting at the valve stem, identify the
first group of four spokes (1-4).
3.
Using a different color for each spoke in the group, draw
an alignment mark across the spoke nipple and onto the
rim.
4.
Continue around the wheel marking the rest of the spokes
the same as they were marked in the previous way.
Wheel Spoke Adjustment
NOTES
•
Do not tighten spoke more than 1/4 turn past alignment
mark. If more tension is needed, label spoke and check
after completing rest of wheel.
•
Do not use the spoke torque wrench to loosen spokes.
Use SPOKE NIPPLE WRENCH (Part No. HD-94681-80)
to loosen spokes.
1.
See
. Starting with the first group of spokes,
loosen spoke (1) using SPOKE NIPPLE WRENCH (Part
No. HD-94681-80) 1/4 turn.
2.
Using SPOKE TORQUE WRENCH (Part No. HD-48985)
tighten spoke (1) to the value listed in
.
a.
While tightening, if the torque wrench clicks before
the alignment marks align, continue to turn the spoke
nipple until the marks align.
b.
If the alignment marks align and the torque specifica-
tion has not been reached, continue to tighten the
spoke nipple until the correct torque is achieved, but
do not turn spoke nipple more then 1/4 turn past
alignment mark.
3.
Repeat previous two steps for spoke (4) in the same group.
4.
Continue around the wheel checking spokes 1 and 4 until
all groups are done.
5.
Repeat procedure for spokes (2, 3) in each group.
NOTE
When checking any spokes that were labeled, make sure to
use the original alignment mark.
6.
Check spokes, if any, that were labeled as not reaching
the proper torque value after tightening 1/4 turn past
alignment mark.
a.
Loosen spoke 1/4 turn past original alignment mark
using SPOKE NIPPLE WRENCH (Part No. HD-94681-
80).
b.
While tightening, if the torque wrench clicks before
the alignment marks align, continue to turn the spoke
nipple until the marks align.
c.
If the alignment marks align and the torque specifica-
tion has not been reached, continue to tighten the
spoke nipple until the correct torque is achieved, but
do not turn spoke nipple more then 1/4 turn past
alignment mark.
7.
True the wheel. See
Table 1-9. Spoke Nipple Torque Specification
MINIMUM TORQUE
RIM TYPE
55
in-lbs
(6.2 Nm)
All
1
3
2
4
sm06507
Figure 1-18. Tightening Laced Wheels (typical)
2013 Sportster Service: Maintenance 1-25
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
FUEL
SYSTEM
1.9
PRIMARY CHAIN
FREE PLAY ADJUSTMENT
TORQUE VALUE
FASTENER
27.1-33.9 Nm
20-25 ft-lbs
Primary chain adjuster locknut
10.2-13.6 Nm
90-120
in-lbs
Primary chain inspection cover
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove the primary chain inspection
cover (1).
NOTE
Rotate the engine to measure free play at several chain posi-
tions.
3.
See
. Through the inspection opening, measure
chain free play at the tightest position.
NOTE
Factory Setting: The factory sets initial cold engine free play
to 1/4-3/8 in (6.35-9.53 mm). With the engine cold, measure
free play on a primary chain that has never been adjusted:
•
Less than 1/4 in (6.35 mm): Adjust to specification.
•
Between 1/4 in (6.35 mm) and 3/8 in (9.53 mm): Do NOT
adjust.
Do not adjust the primary chain tighter than specified.
Running chain too tight will result in excessive wear.
(00202a)
4.
If the measurement is not in specification, adjust the
primary chain. Refer to
a.
See
. Loosen the locknut (2).
b.
With a hex key, turn the adjuster screw (3) clockwise
to reduce free play or counterclockwise to increase
free play.
c.
When free play is within specification, hold the
adjuster screw with a hex key and tighten the locknut
to 20-25 ft-lbs (27.1-33.9 Nm).
5.
If the primary chain cannot be adjusted to specification,
replace the chain. See
or
.
6.
Install a
new
gasket and the primary chain inspection
cover. Tighten to 90-120
in-lbs
(10.2-13.6 Nm).
7.
Install main fuse.
3
2
1
sm06896
1. Inspection cover
2. Locknut
3. Adjuster screw
Figure 1-19. Primary Chain Inspection Cover and Adjuster
om00206c
Figure 1-20. Primary Chain Free Play
Table 1-10. Primary Chain Free Play Specifications
mm
in
ENGINE
9.5-12.7
3/8-1/2
Cold
6.3-9.5
1/4-3/8
Hot
1-26 2013 Sportster Service: Maintenance
1.10
TRANSMISSION LUBRICANT
TRANSMISSION LUBRICATION
TORQUE VALUE
FASTENER
10.3-13.6 Nm
90-120
in-lbs
Clutch inspection cover
screws
19.0-40.7 Nm
14-30 ft-lbs
Primary chaincase drain plug
10.3-13.6 Nm
90-120
in-lbs
Clutch inspection cover
screws
Check Lubricant Level
1.
Ride motorcycle until engine is warmed up to normal
operating temperature.
NOTE
Support motorcycle upright to equalize lubricant level in the
transmission compartments.
2.
Position motorcycle upright.
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.
Remove foot controls:
a.
XL Models with Mid-mount Controls:
Remove left
side rider footrest and mounting bracket assembly.
See
2.40 RIDER FOOT CONTROLS: XL MID-MOUNT
.
b.
XR 1200X:
Remove left side rider footrest, mounting
bracket assembly, and shift linkage. See
5.
See
. Remove screws with washers and
remove clutch inspection cover (1).
6.
See
. Verify that lubricant level is even with
bottom of clutch diaphragm spring (1).
When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)
Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incomplete
disengagement, clutch drag and/or difficulty in finding
neutral at engine idle. (00199b)
7.
If the level is low, add FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT through clutch
inspection cover opening. Verify that lubricant level is even
with bottom of clutch diaphragm spring.
8.
Install the clutch inspection cover:
a.
Install a
new
quad ring. Verify that the quad ring is
fully seated in groove of primary cover.
b.
See
. Install cover and tighten screws in
sequence to 90-120
in-lbs
(10.3-13.6 Nm).
9.
Install left side rider footrest:
a.
XL Models with Mid-mount Controls:
Install left
side rider footrest and mounting bracket assembly.
See
2.40 RIDER FOOT CONTROLS: XL MID-MOUNT
b.
XR 1200X:
Install left side rider footrest, mounting
bracket assembly, and shift linkage. See
10. Install main fuse.
11. Run engine. Check for leaks.
3
2
1
om00908
1. Clutch inspection cover
2. Drain plug
3. Primary chain inspection cover
Figure 1-21. Primary Cover: XL Model
2013 Sportster Service: Maintenance 1-27
1
5
4
3
2
om00397
1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Quad ring
4. Primary cover
5. Chaincase lubricant level
Figure 1-22. Chaincase Lubricant Level
Change Lubricant
Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)
1.
Ride motorcycle until engine is warmed up to normal
operating temperature.
2.
Turn the engine off and position motorcycle on jiffy stand.
This will allow the chaincase lubricant to drain out of
transmission.
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.
See
. Position a suitable container under
transmission drain plug (2).
5.
Remove drain plug. Drain lubricant.
6.
Position the motorcycle straight up and level. This allows
additional fluid to be drained from clutch compartment.
NOTE
Dispose of lubricant in accordance with local regulations.
Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)
7.
Clean magnetic drain plug. Replace O-ring if damaged.
8.
Apply LOCTITE 565 THREAD SEALANT and install drain
plug. Tighten to 14-30 ft-lbs (19.0-40.7 Nm).
9.
Remove the clutch inspection cover.
10. See
. Add 1.00 qt (0.95 L) of FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT through clutch inspection cover opening. Verify
that lubricant level is even with bottom of clutch diaphragm
spring (1).
11. Install the clutch inspection cover:
a.
Install a
new
quad ring. Verify that the quad ring is
fully seated in groove of the primary cover.
b.
See
. Install cover and tighten screws in
sequence to 90-120
in-lbs
(10.3-13.6 Nm).
12. Install main fuse.
13. Run engine. Check for lubricant leaks.
6
2
3
1
5
4
6
5
4
1
2
3
sm07590
Figure 1-23. Clutch Inspection Cover Torque Sequence
1-28 2013 Sportster Service: Maintenance
1.11
CLUTCH
ADJUSTMENT
TORQUE VALUE
FASTENER
10.3-13.6 Nm
90-120
in-lbs
Clutch inspection cover
screws
13.6 Nm
120
in-lbs
Clutch cable adjuster jamnut
Release the Clutch Cable Tension
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
XL Models:
See
. Remove cable adjuster from
the frame retaining clips.
3.
See
. Pull the boot (1) away from the cable
adjuster (2).
4.
Loosen the jamnut (3).
5.
Turn the adjuster to loosen the clutch cable at the hand
lever.
sm01436a
Figure 1-24. Clutch Cable Adjuster Location: XL Models
1
4
3
2
sm01437a
1. Rubber boot
2. Cable adjuster
3. Jamnut
4. Cable end
Figure 1-25. Clutch Cable Adjuster
Clutch Adjustment
1.
Access the clutch inspection cover:
a.
XL Models with Mid-mount Controls:
Remove the
clutch side rider footrest and mounting bracket
assembly. See
.
b.
XR 1200X:
Remove the clutch side rider footrest and
shifter mounting bracket and a shift linkage pivot bolt.
See
2.42 RIDER FOOT CONTROLS: XR 1200X
.
2.
Remove the clutch inspection cover. Discard the quad
ring.
3.
See
. Remove the hex lockplate with the spring
(1) from the clutch adjusting screw (2).
4.
Turn the adjusting screw counterclockwise until resistance
is felt and then turn the adjusting screw clockwise 1/4 turn.
5.
Install the hex lockplate with the spring and turn the
adjusting screw clockwise to fit the lockplate onto the flats
of the adjusting screw.
6.
Install the clutch inspection cover.
a.
Install a
new
quad ring in the primary cover.
b.
Install the inspection cover.
c.
Install the screws and tighten in a cross pattern to 90-
120
in-lbs
(10.3-13.6 Nm).
7.
Install the foot controls:
a.
XL Models with Mid-mount Controls:
Install the
footrest and mounting bracket. See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
.
b.
XR 1200X:
Install the rider footrest and shifter
mounting bracket and shift linkage. See
2013 Sportster Service: Maintenance 1-29
2
1
sm01129a
1. Voltage regulator
2. Mounting screw (2)
Figure 6-91. Voltage Regulator Location
INSTALLATION: XL MODELS
TORQUE VALUE
FASTENER
4.1-6.8 Nm
36-60
in-lbs
Voltage regulator mounting
screw
1.
Position voltage regulator close to mounting bracket. Orient
regulator so cooling fins face forward and wiring harnesses
exit regulator body toward right side of vehicle.
2.
Route stator harness down along between right frame
downtube and body of voltage regulator. Route stator
harness connector [47A] toward right side of vehicle.
3.
Mount voltage regulator on mounting bracket between
frame downtubes and secure with mounting screws at two
locations. Tighten to 36-60
in-lbs
(4.1-6.8 Nm).
4.
Plug stator connector [47A] into socket connector [47B].
Fold external locking latch over and lock in place.
5.
Plug voltage regulator DC output connector [77A] into
socket [77B]. Fold external latch over and lock in place.
6.
Install main fuse.
7.
Test charging system. See the electrical diagnostic
manual.
REMOVAL: XR 1200X
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
NOTE
Never pull on wiring when unplugging voltage connector.
2.
See
. Unplug stator connector (4). Carefully
pull barbed cable strap (3) from frame.
3.
See
. Cut cable strap (1). Lift external latch on
connector and separate connector halves.
4.
See
. Remove screws (1) from locations at top
and bottom of voltage regulator (2). Remove regulator
from vehicle, carefully threading harnesses through
opening in regulator mounting bracket.
1
2
3
4
sm05563
1. Oil pressure switch
2. J-clip
3. Barbed cable strap
4. Stator connector [47]
Figure 6-92. Oil Pressure Switch: XR 1200X
1
2
3
4
sm05585
1. Cable strap
2. DC output conector
3. Oil pressure switch, neutral switch harness
4. Oil filter
Figure 6-93. DC Output Connector: XR 1200X
2013 Sportster Service: Electrical 6-61
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