Harley Davidson 2013 Sportster Models. Service Manual — page 24

2013 Sportster Service: Fuel System 4-11

4.5

FUEL TANK: XR 1200X

PURGING AND DISCONNECTING FUEL
SUPPLY HOSE

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)

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

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)

Purge the fuel supply line of high pressure gasoline.

See

Figure 4-12

. Unplug fuel pump connector [141].

Start engine and allow vehicle to run.

When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.

Shut off ignition.

sm06589

Figure 4-12. Fuel Pump Connector Location

Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)

See

. Push up on release sleeve (1) on fuel

pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3). Immedi-
ately clean up any fuel spills.

sm06709a

1. Release sleeve (quick-connect fitting)
2. Fuel supply hose fitting
3. Fuel supply hose
4. Throttle cable retainer

Figure 4-13. Fuel Tank Quick-Connect Fitting

REMOVING FUEL TANK

Purge the fuel supply line of high pressure gasoline. Dis-
connect fuel line from fuel tank. See

6.3 FUSES AND

RELAYS, Main Fuse

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

NOTES

•

If the fuel tank is being removed only to gain access to
items otherwise hidden, it is not necessary to drain the
fuel from the tank. If the fuel tank is to be disassembled
or repaired, drain the fuel tank.

•

Drain fuel into an approved container.

4-12 2013 Sportster Service: Fuel System

Drain fuel tank:

Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.

Position vehicle upright. Remove fuel tank filler cap.

Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.

Direct the pump output into an approved container.

Pump fuel until fuel tank is empty.

Replace fuel tank filler cap.

Immediately wipe up any spilled fuel.

See

. Remove retainer (4) securing throttle

cables to plate on bottom of fuel tank.

NOTE

See

Figure 4-14

. Short screws (2) secure trim ring to fuel tank

cover only. It is not necessary to remove these screws unless
either trim ring or fuel tank cover is being replaced.

See

Figure 4-14

. Remove four long screws (1) that secure

trim ring (4) and fuel tank cover (5) to fuel tank.

Carefully lift fuel tank cover off fuel tank. Slide cover for-
ward slightly as it is lifted to clear sides of fuel tank.

See

Figure 4-15

. Remove vent hose (3) from fuel tank

vent fitting (4). With a gentle twisting motion, pull ground
wire connector [210] (5) straight up off pin on fuel tank
clamp ring (6).

Remove vent hose and ground wire from trough in center
of fuel tank. Pull vent hose and ground wire back out of
the way.

sm04947

1. Screw, long (4)
2. Screw, short (4)
3. Fuel cap
4. Trim ring
5. Fuel tank cover

Figure 4-14. Fuel Cap and Trim Ring

sm04948

1. Fuel tank
2. Fuel cap
3. Vent hose
4. Vent fitting
5. Ground wire connector [210]
6. Clamp ring

Figure 4-15. Fuel Tank Vent Hose and Ground Wire

See

Figure 4-16

. Remove two screws and washers (3)

securing air box to bottom of fuel tank.

10. Remove screw with washer (4) from rear of fuel tank.

Remove protective plastic cap (not shown) from threaded
end of screw (6). Remove screw, washers and locknut
from the front of the fuel tank.

11. See

. Remove throttle cable retainer (4) from

fuel tank.

2013 Sportster Service: Fuel System 4-13

sm04952

1. Fuel tank
2. Air box
3. Screw w/washer (2)
4. Screw w/washer
5. Rubber grommet
6. Screw w/washers and locknut

Figure 4-16. Fuel Tank and Air Box Mounting Fasteners

12. Lift fuel tank off motorcycle.

NOTE

See

Figure 4-19

. Metal bushings (4) inside the grommets (3)

may fall when fuel tank is lifted off vehicle. Make sure they do
not fall out and become lost.

13. Remove fuel pump assembly from fuel tank. See

4.16 FUEL PUMP

DISASSEMBLE FUEL TANK

See

Figure 4-17

. Remove filler cap (1) with O-ring (2).

Remove screws (7) and clamp ring (3).

Remove top ring (4).

Remove O-ring (5).

sm05448

1. Filler cap
2. O-ring
3. Clamp ring
4. Top ring
5. O-ring
6. Fuel tank
7. Screw (6)

Figure 4-17. Fuel Tank Assembly

CLEANING AND INSPECTION

Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.

Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.

Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.

Inspect the fuel tank for leaks or other damage. Replace
the tank if necessary.

4-14 2013 Sportster Service: Fuel System

ASSEMBLE FUEL TANK

TORQUE VALUE

FASTENER

4.5-5.1 Nm

40-45

in-lbs

Filler housing screws

See

Figure 4-17

. Install

new

O-ring (5) on the fuel tank

(6). Verify that it is seated properly.

Install top ring and clamp ring with screws (7).

See

Figure 4-18

. Tighten screws in the sequence shown

to 40-45

in-lbs

(4.5-5.1 Nm).

See

Figure 4-17

. Install filler cap (1) with a

new

O-ring (2).

sm05461

Figure 4-18. Filler Housing Torque Sequence

INSTALLING FUEL TANK

TORQUE VALUE

FASTENER

4.1-6.7 Nm

36-60

in-lbs

Air box to bracket fasteners:
XR 1200X

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fastener: XR 1200X

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fastener: XR 1200X

2.7-3.4 Nm

24-30

in-lbs

Fuel tank cover screw: XR
1200X

NOTE

Be sure that wiring harnesses do not get pinched between fuel
tank and frame during tank installation.

Install fuel pump into fuel tank using

new

gasket. See

4.16 FUEL PUMP

See

Figure 4-19

. Install rubber grommets (3) in both front

mounting holes of fuel tank. Insert metal bushings (4) into
rubber grommets, oriented as shown. Verify that the clip
nut (5) is installed on frame bracket.

NOTES

•

Verify that the ignition coil bracket is positioned between
the tank mount and the frame.

•

Verify that the air box mounting brackets are mated.

Position fuel tank on motorcycle.

Insert screw (6) with washer (2) through fuel tank front
mounting brackets and vehicle frame. Install remaining
washer and locknut (7) on other end of screw. Do not
tighten at this time.

Secure pump harness to main harness retainer located
under fuel tank.

Install rubber grommets (3) in rear mounting hole of fuel
tank.

NOTE

Verify that the air box grommet is securely installed on induction
module and air box opening. An improperly seated grommet
could lead to accelerated engine wear. See

4.3 AIR CLEANER

ASSEMBLY, XR 1200X

Secure air box to brackets on bottom of fuel tank. Tighten
to 36-60

in-lbs

(4.1-6.7 Nm).

Mount the fuel tank.

Locate the metal bushing (4) inside the rear lower
rubber grommet (3) of fuel tank.

Install screw (1), washer (2) and upper grommet (3).

Thread into clip nut (5). Tighten to 15-20 ft-lbs (20.3-
27.1 Nm).

Tighten front screw (6) and locknut (7) to 15-20 ft-lbs
(20.3-27.1 Nm).

See

. Secure throttle cables to bottom of fuel

tank using a

new

loop retainer.

10. See

Figure 4-15

. Connect vent hose (3) and ground wire

(5) as shown. Route ground wire and vent hose in trough
in top of tank.

11. See

Figure 4-14

. Install fuel tank cover and secure with

four screws (1). Tighten screws to 24-30

in-lbs

(2.7-3.4

Nm).

12. Connect fuel pump connector [141].

13. Connect fuel supply fitting. See

1200X, Connecting Fuel Hose and Filling Fuel Tank

2013 Sportster Service: Fuel System 4-15

sm05411

1. Rear screw
2. Washer (3)
3. Rubber grommet (6)
4. Metal bushing (3)
5. Clip nut
6. Front screw
7. Locknut
8. Cap

Figure 4-19. Fuel Tank Mounting

CONNECTING FUEL HOSE AND FILLING
FUEL TANK

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)

See

. Connect the fuel hose fitting:

Push up on release sleeve (1).

Push fuel hose fitting (2) into fuel pump module fuel
pump quick-connect fitting.

Pull down on release sleeve to lock quick-connect
fitting.

Tug on fuel hose fitting to make sure it is securely
locked in place.

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)

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)

Fill fuel tank and carefully inspect for leaks around fuel
pump module.

Install main fuse.

Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting and
induction module. Turn ignition switch OFF.

Install left side cover.

4-16 2013 Sportster Service: Fuel System

4.6

THROTTLE POSITION SENSOR (TPS)

GENERAL

See

Figure 4-20

Figure 4-21

. The TPS is located on the side

of the induction module. The TPS monitors the physical position
of the throttle shaft. See the electrical diagnostic manual.

sm06853a

Figure 4-20. TPS Location: XL Models

sm06564a

Figure 4-21. TPS Location: XR 1200X

REMOVAL: XL MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

See

Figure 4-22

. Unplug TPS harness connector [88B]

from connector socket [88A] (4). Cover both connectors
with tape.

Remove two screws (5). Detach TPS (3) from induction
module (1).

2013 Sportster Service: Fuel System 4-17

sm01617

1. Induction module
2. Intake manifold
3. TPS
4. TPS connector socket [88A]
5. Screw (2)

Figure 4-22. Throttle Position Sensor (TPS) Removal: XL

Models

INSTALLATION: XL MODELS

TORQUE VALUE

FASTENER

4.0 Nm

in-lbs

TPS screw: XL Models

NOTES

•

Throttle must be closed to install the TPS.

•

See

Figure 4-22

. Note orientation of TPS (3) relative to

induction module (1) body. The connector socket is at
approximately the 7 o'clock position, facing toward intake
manifold (2).

See

Figure 4-23

. Fit pocket (3) of TPS (2) over throttle

shaft (4). Orient TPS correctly and line up mounting holes
in sensor with holes in body of induction module (1).

Make sure TPS body is flush against mounting boss on
induction module body. Install two screws (5) to fasten
sensor to induction module. Tighten screws to 35

in-lbs

(4.0 Nm).

Open and close throttle plates and check for proper oper-
ation. Be sure mechanism operates smoothly without
binding or sticking.

Connect TPS harness socket connector [88B] to sensor
pin connector [88A].

Install air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

Install main fuse.

Close left side cover.

Start motorcycle. Check throttle operation and idle speed.

Check for leaks at the quick connect fitting and at the
induction module.

sm01618

1. Induction module
2. TPS
3. Pocket
4. Throttle shaft
5. Screw (2)

Figure 4-23. Throttle Position Sensor (TPS) Installation:

XL Models

REMOVAL: XR 1200X

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.5 FUEL TANK: XR 1200X

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove fuel tank and air box. See

4.3 AIR CLEANER ASSEMBLY, XR 1200X

1200X

and

4.9 INDUCTION MODULE: XR 1200X

4-18 2013 Sportster Service: Fuel System

See

Figure 4-24

. Remove induction module from vehicle.

See

Remove two screws (4) and detach TPS (2) from induction
module (1).

sm06590

1. Induction module
2. TPS
3. TPS connector socket [88A]
4. Screw (2)

Figure 4-24. Throttle Position Sensor (TPS) Removal: XR

1200X

INSTALLATION: XR 1200X

TORQUE VALUE

FASTENER

3.3 Nm

in-lbs

TPS screw: XR 1200X

NOTES

•

Throttle must be closed for installation of throttle position
sensor.

•

See

Figure 4-24

. Note installed orientation of TPS (2) rel-

ative to induction module (1) body. The connector socket
is at approximately the 5:00 o'clock position.

See

Figure 4-25

. Place sensor over throttle shaft with the

connector housing (1) facing toward the mounting flange
(2).

Rotate the TPS counterclockwise into position as shown
in

Figure 4-24

Make sure TPS body is flush against mounting boss on
induction module body. Install two screws (4). Tighten to
29

in-lbs

(3.3 Nm).

Open and close throttle plate. Be sure mechanism oper-
ates smoothly without binding or sticking.

sm05425

1. Connector housing
2. Mounting flange

Figure 4-25. Throttle Position Sensor (TPS) Installation:

XR 1200X

Install induction module. See

4.9 INDUCTION MODULE:

XR 1200X

Install air box assembly and fuel tank. See

4.3 AIR

CLEANER ASSEMBLY, XR 1200X

and

4.5 FUEL TANK:

XR 1200X

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)

Connect fuel hose to fuel pump module. Fill fuel tank and
carefully check for leaks around fuel hose fitting. See

4.5 FUEL TANK: XR 1200X

Install main fuse.

Turn ignition switch on. Check for leaks at the quick con-
nect fitting and at the induction module.

10. Start motorcycle. Check throttle operation and idle speed.

2013 Sportster Service: Fuel System 4-19

4.7

ENGINE TEMPERATURE (ET) SENSOR

GENERAL

See

Figure 4-26

. The ET sensor is located in the top of the

rear cylinder head. See the electrical diagnostic manual.

sm01635

Figure 4-26. ET Sensor Location

REMOVAL

TOOL NAME

PART NUMBER

TEMPERATURE SENSOR SOCKET

HD-48116-A

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

1200X

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove fuel tank. See

4.5 FUEL TANK: XR 1200X

See

Figure 4-27

Figure 4-28

. Disconnect the ET sensor

connector [90] (3) located on right side of H-bracket/ECM
caddy.

Cut barbed cable strap (2) to free sensor harness from H-
bracket/ECM caddy.

XR 1200X:

See

Figure 4-28

. Disconnect the breather hose

(1) from the rear cylinder to gain access to the sensor.

Remove ET sensor as follows:

Attach a universal joint, a 6 inch extension and a
ratchet to the TEMPERATURE SENSOR SOCKET
(Part No. HD-48116-A).

See

Figure 4-29

. Fit engine temperature sensor har-

ness (2) into slot in temperature sensor socket (3).

Slide socket down harness, through square hole in
center of rear rocker cover assembly and fit onto ET
sensor (1).

See

Figure 4-30

. Once you have installed the temper-

ature sensor socket (1) onto the sensor (4), secure
the sensor harness to the socket extension (3) with
tape (6). This will facilitate removal of the sensor.

Remove ET sensor from rear cylinder head.

sm06586

1. Harness loop
2. Barbed cable strap
3. Engine temperature sensor connector location

Figure 4-27. ET Sensor Harness: XL Models

4-20 2013 Sportster Service: Fuel System

sm05417a

1. Breather hose
2. Barbed cable strap
3. Sensor harness connector [90]
4. Harness Loop

Figure 4-28. ET Sensor Harness: XR 1200X

sm01638

1. ET sensor
2. Sensor harness
3. Temperature sensor socket

Figure 4-29. Installing ET Sensor Socket (XL shown)

sm01641

1. Temperature sensor socket
2. Universal joint
3. Socket extension
4. Engine temperature sensor
5. Sensor harness
6. Tape

Figure 4-30. Tape ET Sensor Harness to Extension

INSTALLATION

TORQUE VALUE

FASTENER

13.6-19.0 Nm

120-168

in-lbs

ET sensor

See

Figure 4-30

. Fit engine the ET sensor (4) into temper-

ature sensor socket (1).

NOTE

The sensor harness MUST turn with the socket and extension.
The harness may be damaged when the sensor is installed.

Holding sensor in place in socket, wrap a piece of tape
(6) around sensor harness (5) and socket extension (3).

Slide assembly down into top of rear head and carefully
thread sensor into head. Do not cross-thread. Tighten to
120-168

in-lbs

(13.6-19.0 Nm).

NOTE

See

Figure 4-27

. Make sure there is a loop (4) in sensor har-

ness when securing harness. If harness is pulled tight or con-
tacting the rear rocker cover, it could be damaged during
vehicle operation.

See

Figure 4-27

Figure 4-28

. Use a barbed cable strap

(2) to secure sensor harness. Position cable strap so
harness forms a loop (4) between sensor and cable strap.

Connect sensor connector [90] (3) and secure to H-
bracket/ECM caddy.

Install fuel tank and connect fuel supply hose. See

1200X

Install main fuse.

Close left side cover.

2013 Sportster Service: Fuel System 4-21

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)

Install seat.

4-22 2013 Sportster Service: Fuel System

4.8

INDUCTION MODULE: XL MODELS

REMOVAL

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

Remove seat.

Pull fuel tank back to access induction module.

Loosen (but do not remove) front fuel tank mounting
screw.

Remove rear fuel tank mounting screw, washers and
nut.

Carefully pivot rear of fuel tank upward and prop in
position. See

See

Figure 4-31

. Remove screw (2) and mounting bracket

(1).

sm01574

1. Mounting bracket
2. Screw

Figure 4-31. Induction Module Mounting Bracket

See

Figure 4-32

. Unplug the following connectors:

Front fuel injector (4) connector [84],

Rear fuel injector (5) connector [85],

TMAP sensor (6) connector [80],

IAC (7) connector [87],

TPS (8) connector [88].

EVAP Controlled Models:

remove purge hose from fitting

(9) on induction module (1).

2013 Sportster Service: Fuel System 4-23

sm06573

1. Induction module
2. Intake manifold
3. Throttle cable bracket
4. Front fuel injector [84A]
5. Rear fuel injector [85A]
6. TMAP sensor [80A]
7. IAC [87A]
8. TPS [88A]
9. Purge hose fitting (EVAP controlled models)
10. Fuel supply hose
11. Throttle wheel
12. Fuel rail

Figure 4-32. Induction Module Assembly

See

Figure 4-33

. Slide rubber boot off idle control cable

assembly (1).

10. Loosen jamnut (3).

11. Loosen cable adjuster as far as possible to provide max-

imum slack in idle cable.

sm01579

1. Idle control (pull close) cable assembly
2. Cable adjuster
3. Jamnut

Figure 4-33. Idle Control Cable Adjustment

12. See

Figure 4-34

. Loosen two screws (2) securing intake

manifold to heads on left side of vehicle, but do not remove
screws.

13. See

Figure 4-35

. Remove two screws (3) securing intake

manifold to heads on right side of vehicle.

14. Pull mounting flanges (4) away from heads as much as

possible and pull induction module and intake manifold
assembly toward the right side, away from vehicle.

sm06569

1. Intake manifold
2. Screw (2)

Figure 4-34. Intake Manifold Mounting Screws: Left Side

4-24 2013 Sportster Service: Fuel System

sm01583

1. Induction module
2. Intake manifold
3. Screw (2)
4. Mounting flange (2)

Figure 4-35. Intake Manifold Mounting Screws: Right Side

15. See

Figure 4-35

. Remove throttle cable (5) from throttle

wheel (7)

Lift throttle cable housing (1) up out of cable guide
(3) in throttle/idle cable bracket (2).

Slide throttle cable (5) out through slot (4) in cable
guide.

Unwind throttle cable from groove in throttle wheel
(7).

Slide cable out through slot (8) and remove throttle
cable barrel (6) from throttle wheel.

sm01584

1. Throttle cable housing
2. Throttle/idle cable bracket
3. Cable guide
4. Slot
5. Throttle cable
6. Cable barrel
7. Throttle wheel
8. Slot

Figure 4-36. Removing/Installing Throttle Cable

16. See

Figure 4-37

. In a similar fashion, remove idle cable

(3) from throttle wheel (6):

Lift idle cable housing (1) and spring (2) up out of
cable guide (7) in throttle/idle cable bracket.

Slide idle cable (3) out through slot in cable guide.

Unwind idle cable from groove in throttle wheel (6).

Slide cable out through slot (5) and remove idle cable
barrel (4) from throttle wheel.

17. Remove induction module and intake manifold from

vehicle.

sm01585

1. Idle cable housing
2. Spring
3. Idle cable
4. Cable barrel
5. Slot
6. Throttle wheel
7. Cable guide

Figure 4-37. Removing/Installing Idle Cable

DISASSEMBLY

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

Gasoline can drain from the fuel line when disconnected
from induction module. Gasoline is extremely flammable
and highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00269a)

Remove fuel hose, fuel rail and fuel injectors. See

4.15 FUEL INJECTORS

See

Figure 4-38

. Remove screws (1, 2) and cable bracket

(3) from induction module (4).

NOTE

When removing the IAC, the mounting screws MUST be heated
to soften the thread sealant and avoid breakage during removal.
Use ONLY HEAT GUN (Part No. HD-25070) to heat the screws.
NEVER use an open flame.