Harley Davidson 2013 Sportster Models. Service Manual — page 42
sm06554
Figure 5-96. Assembling Crankcases With Crankshaft
Guide Tool (Part No. HD-42326-A)
14
13
12
11
9
10
15
4
3
2
1
5
6
7
8
16
17
sm01380b
Figure 5-97. Crankcase Fastener Torque Sequence
SHIFTER SHAFT INSTALLATION
TORQUE VALUE
FASTENER
44.8-50.2 Nm
33-37 ft-lbs
Countershaft retaining screw
1.
See
. Correctly install shifter return spring onto
the reverse side of the shifter shaft assembly before pla-
cing shaft in left crankcase half.
NOTE
See
. Verify shifter shaft return spring assembly
and installation. Incorrect spring installation could cause prob-
lems with shifting.
2.
See
. Press the ratchet arms and insert shaft
assembly into the bushing in the left case half and release.
Ratchet arms should now be inside the end plate of the
shifter drum contacting the shifter drum pins.
3.
See
. Apply several drops of LOCTITE 262
HIGH STRENGTH THREADLOCKER AND SEALANT
(red) to last few threads of countershaft retaining screw.
Thread screw into end of shaft.
4.
Place transmission in gear and tighten screw to 33-37 ft-
lbs (44.8-50.2 Nm).
5.
Install transmission sprocket. See
6.
Continue assembling engine. See
and
7.
Install primary chain and engine sprocket, clutch assembly,
and primary cover. See
or
.
8.
Install engine in chassis. See
.
sm01467
Figure 5-98. Shifter Shaft Return Spring (Correctly
Installed)
5-54 2013 Sportster Service: Drive/Transmission
sm01468
Figure 5-99. Shifter Shaft Return Spring (Incorrectly
Installed)
sm01323a
Figure 5-100. Installing Shifter Shaft Assembly
sm01324b
Figure 5-101. Countershaft Retaining Screw
2013 Sportster Service: Drive/Transmission 5-55
5.15
TRANSMISSION SPROCKET
REMOVAL
TOOL NAME
PART NUMBER
ENGINE CRADLE
HD-42310-45
FINAL DRIVE SPROCKET HOLDING
TOOL REACTION ADAPTER
HD-46282-1A
FINAL DRIVE SPROCKET HOLDING
TOOL
HD-46282-A
MAINSHAFT LOCKNUT WRENCH
HD-46288
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
Preparation
1.
Remove main fuse.
2.
Shift transmission into neutral.
XL Models
1.
Remove rear muffler and rear exhaust pipe. See
4.13 EXHAUST SYSTEM: XL MODELS
.
2.
See
. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3) and remove sprocket cover (1).
3.
Remove belt guard. See
4.
Remove rear drive belt from transmission sprocket. Pull
belt back out of the way. Do not bend belt too tightly or
twist belt. See
.
5.
See
. Remove screw and washer (6) from
exhaust interconnect bracket.
XR 1200X
1.
Remove exhaust system. See
2.
Remove three screws securing sprocket cover to engine
crankcase. Remove sprocket cover.
3.
Remove belt guard. See
4.
Remove the rear brake master cylinder assembly:
a.
Remove two screws securing rear brake master cyl-
inder assembly, rider footrest and mounting bracket
to vehicle's frame.
b.
Carefully pull assembly back out of the way. Secure
to frame with cable strap or bungee cord.
c.
Do not kink or bend metal portion of brake line.
5.
Remove rear drive belt from transmission sprocket. Pull
belt back out of the way. Do not bend belt too tightly or
twist belt. See
.
4
3
2
1
5
6
sm01469
1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw
Figure 5-102. Sprocket Cover: XL Models
2
1
5
3
4
6
sm01324a
1. Main drive gear shaft
2. Transmission sprocket
3. Transmission sprocket nut
4. Lockplate
5. Screw (2)
6. Screw and washer
Figure 5-103. Transmission Sprocket Assembly: All Models
5-56 2013 Sportster Service: Drive/Transmission
All Models
1.
See
. Remove two screws (5) and sprocket
lockplate (4).
NOTES
•
See
. On XR 1200X and XL models without
passenger footrests, install FINAL DRIVE SPROCKET
HOLDING TOOL REACTION ADAPTER (Part No. HD-
46282-1A) into bottom footrest bracket hole in frame. Place
handle of tool underneath adapter.
•
If the engine is mounted in the ENGINE CRADLE (Part
No. HD-42310-45), the rear crankcase support serves as
a tool stop for the sprocket holding tool.
2.
See
. Install the FINAL DRIVE SPROCKET
HOLDING TOOL (Part No. HD-46282-A) (1). Hold the
sprocket nut with MAINSHAFT LOCKNUT WRENCH (Part
No. HD-46288) (2). Use a breaker bar (3) to loosen the
nut. Place handle of sprocket holding tool under bottom
of footrest bracket. Turn nut
clockwise
to remove it.
1
3
2
sm01326a
1. Transmission sprocket holding tool
2. Mainshaft locknut wrench
3. Breaker bar
Figure 5-104. Removing Transmission Locknut
1
2
sm05495
1. Transmission sprocket holding tool
2. Sprocket holding tool adapter
Figure 5-105. Sprocket Holding Tool and Adapter
(installation XR 1200X)
INSTALLATION
TOOL NAME
PART NUMBER
TRANSMISSION SPROCKET
HOLDING TOOL
HD-46282
SPROCKET HOLDING TOOL
ADAPTER
HD-46282-1A
MAINSHAFT LOCKNUT WRENCH
HD-46288
TORQUE VALUE
FASTENER
68 Nm
50 ft-lbs
Transmission sprocket nut
10.3-13.6 Nm
90-120
in-lbs
Transmission sprocket lock-
plate fastener
40.7-44.8 Nm
30-33 ft-lbs
Muffler interconnect bracket
mounting screw: XR 1200X
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket
fastener: XR 1200X
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
61-68 Nm
45-50 ft-lbs
Footrest mount fastener
40.7-44.8 Nm
30-33 ft-lbs
Sprocket cover, rear screw
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
Preparation
1.
See
. Install transmission sprocket (2) onto
main drive gear shaft (1).
NOTE
See
. On XR 1200X and XL models without pas-
senger footrests, screw SPROCKET HOLDING TOOL
ADAPTER (Part No. HD-46282-1A) into top footrest bracket
hole in frame. Place handle of tool on top of adapter.
2.
Shift transmission into neutral. Apply LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red) to
the
left-hand threads
of transmission sprocket nut (3).
Apply a thin film of SCREAMIN' EAGLE ASSEMBLY LUBE
to the back face of the sprocket nut. Turn the nut
counterclockwise
to install it onto main drive gear shaft.
a.
See
. Use TRANSMISSION SPROCKET
HOLDING TOOL (Part No. HD-46282) (1), MAIN-
SHAFT LOCKNUT WRENCH (Part No. HD-46288)
(2), and a torque wrench (3). Place handle of sprocket
holding tool on top of footrest bracket. Tighten nut to
50 ft-lbs (68 Nm) initial torque, ONLY.
b.
See
. Scribe a line on the transmission
sprocket nut and continue the line on the transmission
sprocket as shown.
c.
Tighten the transmission sprocket nut an additional
30-40 degrees.
NOTE
The lockplate has can be turned to either side to align the
screw holes. If the screw holes cannot be properly aligned,
2013 Sportster Service: Drive/Transmission 5-57
tighten the nut slightly until the holes align. Do not exceed
45 degrees. Never LOOSEN nut to align the screw holes.
d.
See
. Install lockplate (4) over nut (3) so
that two of lockplate's four drilled holes (diagonally
opposite) align with sprocket's (2) two tapped holes.
3
2
1
sm01327a
1. Transmission sprocket holding tool
2. Mainshaft locknut wrench
3. Torque wrench
Figure 5-106. Tightening Transmission Locknut: All Models
45
30
2
1
3
sm01470
1. Transmission sprocket
2. Sprocket nut
3. Line scribed on nut and sprocket
Figure 5-107. Transmission Sprocket Nut Final Tightening
Procedure
NOTE
Always install BOTH screws to secure the lockplate.
3.
Install socket head screws (5) through two of the four holes
in lockplate, then into two corresponding tapped holes in
sprocket. Tighten to 90-120
in-lbs
(10.3-13.6 Nm).
4.
XR 1200X and XL Models without Passenger Footrests:
Remove SPROCKET HOLDING TOOL ADAPTER (Part
No. HD-46282-1A).
XL 1200X
1.
See
. Install screw and washer (6) to secure
muffler interconnect bracket to engine crankcase. Tighten
to 30-33 ft-lbs (40.7-44.8 Nm).
2.
Install rear drive belt onto transmission sprocket. See
3.
Adjust rear belt deflection and rear wheel alignment. See
.
4.
Install belt guard. See
.
5.
See
. Install sprocket cover (1). Secure with
two screws (2, 3). Note that long screw goes in top hole,
short screw in bottom hole. Do not tighten screws at this
time.
6.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120
in-lbs
(9.0-13.6 Nm).
7.
Install
rear
exhaust
pipe
and
rear
muffler.
See
4.13 EXHAUST SYSTEM: XL MODELS
.
XR 1200X
1.
Install rear drive belt onto transmission sprocket. See
2.
Adjust rear belt deflection and rear wheel alignment. See
.
3.
Attach rear brake master cylinder, rider footrest and
mounting bracket assembly to frame with two screws.
Tighten to 45-50 ft-lbs (61-68 Nm).
4.
Install belt guard. See
.
5.
Install sprocket cover.
a.
Install longer screw in top hole.
b.
Install shorter one in bottom hole.
c.
Install larger diameter fastener in rear hole.
d.
Tighten rear (larger dia.) fastener to 30-33 ft-lbs (40.7-
44.8 Nm).
e.
Tighten forward and lower (smaller) screws to 80-120
in-lbs
(9.0-13.6 Nm).
6.
Install exhaust system. See
All Models
Install main fuse.
5-58 2013 Sportster Service: Drive/Transmission
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ELECTRICAL
6.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
6.24 ALTERNATOR, Assembly and Installation
13.6-15.8 Nm
120-140
in-lbs
Alternator rotor to sprocket screw
6.24 ALTERNATOR, Assembly and Installation
3.4-4.5 Nm
30-40
in-lbs
Alternator stator mounting screw
6.8 BATTERY CABLES, Installation
6.2-8.5 Nm
55-75
in-lbs
Battery negative cable to crankcase nut
6.8 BATTERY CABLES, Installation
6.8-7.9 Nm
60-70
in-lbs
Battery negative terminal screw
6.8 BATTERY CABLES, Installation
6.8-9.6 Nm
60-85
in-lbs
Battery positive cable to starter post
locknut
6.8 BATTERY CABLES, Installation
6.8-7.9 Nm
60-70
in-lbs
Battery positive terminal screw
6.8 BATTERY CABLES, Installation
4.1-6.8 Nm
36-60
in-lbs
Battery strap screw
6.9 BATTERY TRAY, Installation
10.9-17.6 Nm
96-156
in-lbs
Battery tray mounting fasteners
6.9 BATTERY TRAY, Installation
3.4-4.5 Nm
30-40
in-lbs
Brake hose clamp to battery tray screw
6.21 REAR STOP LAMP SWITCH, Replacement
2.3-2.8 Nm
20-25
in-lbs
Brake master cylinder reservoir, rear,
mounting screw
6.22 CRANK POSITION SENSOR (CKP), Installa-
tion
10.3-13.6 Nm
90-120
in-lbs
CKP screw
6.14 HEADLAMP, Headlamp Mounts
4.0-7.3 Nm
45-65
in-lbs
Clutch cable guide: XL 1200C/C
ANV/CP/CA/CB
6.13 IGNITION COIL, Installation
4.0-5.1 Nm
35-45
in-lbs
Coil mounting bracket screw
6.13 IGNITION COIL, Installation
2.7-8.1 Nm
24-72
in-lbs
Coil mounting screw
6.13 IGNITION COIL, Installation
2.7-8.1 Nm
24-72
in-lbs
Coil mounting screw
6.20 REAR LIGHTING CONVERTER MODULE:
XL 883N, XL 1200X/V (DOM), Installation
4.1-6.8 Nm
36-60
in-lbs
Converter module bracket fasteners, rear
lighting
6.9 BATTERY TRAY, Installation
8.1-10.8 Nm
72-96
in-lbs
ECM caddy fastener
6.20 REAR LIGHTING CONVERTER MODULE:
XL 883N, XL 1200X/V (DOM), Installation
8.1-10.8 Nm
72-96
in-lbs
ECM caddy fastener
6.27 MAIN WIRING HARNESS, Installation
8.1-10.8 Nm
72-96
in-lbs
ECM caddy fastener
6.6 ELECTRONIC CONTROL MODULE
(ECM), Installation
3.4-6.8 Nm
30-60
in-lbs
ECM cover fastener: XL Models
6.6 ELECTRONIC CONTROL MODULE
(ECM), Installation
2.0-2.5 Nm
18-22
in-lbs
ECM fasteners: XR 1200X
6.17 LICENSE PLATE LAMP MODULE: XL 883N,
XL 1200X/V, Installation: HDI
2.3-2.8 Nm
20-25
in-lbs
Fender brace, rear, screw
6.17 LICENSE PLATE LAMP MODULE: XL 883N,
XL 1200X/V, Installation: HDI
14.9-24.4 Nm
132-216
in-lbs
Fender support, rear, screw: XL 883N
6.18 FRONT TURN SIGNALS, XL 1200X
40.7-47.5 Nm
30-35 ft-lbs
Fork bracket pinch screw
6.15 INDICATOR LAMP MODULE, Replacement:
XL 883R/L/N, XL 1200X/V, XL 1200CP/CB with
Mini-Ape Handlebar/XL883N - Tighten rear first,
front second.
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp screw
6.15 INDICATOR LAMP MODULE, Replacement:
XL 883R/L/N, XL 1200X/V, XL 1200CP/CB with
Mini-Ape Handlebar/Tighten rear first, front second:
XL883N.
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp screw
2013 Sportster Service: Electrical 6-1
NOTES
TORQUE VALUE
FASTENER
6.15 INDICATOR LAMP MODULE, Replacement:
XR 1200X
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp screw
6.34 RIGHT HANDLEBAR SWITCHES, Installation
12.2-14.9 Nm
108-132
in-lbs
Handlebar control lever clamp screw
6.35 LEFT HANDLEBAR SWITCHES, Installation
12.2-14.9 Nm
108-132
in-lbs
Handlebar control lever clamp screw
6.15 INDICATOR LAMP MODULE, Replacement:
XL 1200C/C ANV/CP/CA except with Mini-Ape
Handlebar/XL1200C
16.3 -24.4 Nm
12-18 ft-lbs
Handlebar riser clamp screw
6.15 INDICATOR LAMP MODULE, Replacement:
XL 1200C/C ANV/CP/CA except with Mini-Ape
Handlebar/XL1200C
16.3 -24.4 Nm
12-18 ft-lbs
Handlebar riser clamp screw
6.15 INDICATOR LAMP MODULE, Replacement:
XL 1200C/C ANV/CP/CA except with Mini-Ape
Handlebar/XL1200C
0.9-1.4 Nm
8-12
in-lbs
Handlebar riser cover screw
6.14 HEADLAMP, Headlamp Mounts
41-47 Nm
30-35 ft-lbs
Headlamp assembly: XL 1200X
6.14 HEADLAMP, Headlamp Mounts
41-47 Nm
30-35 ft-lbs
Headlamp assembly: XL 1200X
6.14 HEADLAMP, Headlamp Mounts
14-27 Nm
120-240
in-lbs
Headlamp clamp nut: XL 883L/N/R, XR
1200X
6.14 HEADLAMP, Headlamp Mounts
41-47 Nm
30-35 ft-lbs
Headlamp mount: XL
1200V/C/CP/CA/CB
6.14 HEADLAMP, Headlamp Mounts
41-47 Nm
30-35 ft-lbs
Headlamp mount: XL 1200X
6.14 HEADLAMP, Headlamp Mounts
14-22 Nm
120-192
in-lbs
Headlamp upper bracket fasteners: XL
883L/R/N, XR 1200X
6.14 HEADLAMP, Headlamp Mounts
14-22 Nm
120-192
in-lbs
Headlamp visor: XL 1200C/C
ANV/CP/CA/CB
6.32 HORN, Replacement: Side Mount
6.8-20.4 Nm
60-180
in-lbs
Horn, side mounted, acorn nut
6.32 HORN, Replacement: Side Mount
9.0-11.3 Nm
80-100
in-lbs
Horn, side mounted, stud nut
6.32 HORN, Replacement: Front Mount
4.1-5.4 Nm
36-48
in-lbs
Horn mounting screw
6.28 ELECTRICAL CADDIES, Wire Harness
Caddy: XL Models
4.0-5.1 Nm
35-45
in-lbs
Ignition switch bracket screw
6.11 IGNITION SWITCH, Installation
4.0-5.1 Nm
35-45
in-lbs
Ignition switch mounting screw
6.28 ELECTRICAL CADDIES, Wire Harness
Caddy: XR 1200X
4.0-5.1 Nm
35-45
in-lbs
Ignition switch mounting screw
6.29 JIFFY STAND SENSOR (JSS): INTERNA-
TIONAL MODELS, Installation
10.9-13.6 Nm
96-120
in-lbs
JSS screw
6.17 LICENSE PLATE LAMP MODULE: XL 883N,
XL 1200X/V, Installation: HDI
1.2-1.3 Nm
14-16
in-lbs
License plate lamp housing screw: XL
883N
6.26 NEUTRAL INDICATOR SWITCH, Replace-
ment
13.6-20.3 Nm
120-180
in-lbs
Neutral indicator switch
6.31 OIL PRESSURE SWITCH, Installation
5.6-7.9 Nm
50-70
in-lbs
Oil pressure switch
6.31 OIL PRESSURE SWITCH, Installation
17.6-23.0 Nm
13-17 ft-lbs
Oil pressure switch adapter: XR 1200X
6.17 LICENSE PLATE LAMP MODULE: XL 883N,
XL 1200X/V, Installation: Domestic Only
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
6.17 LICENSE PLATE LAMP MODULE: XL 883N,
XL 1200X/V, Installation: HDI
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
6.10 STARTER, Solenoid
7.3-9.0 Nm
65-80
in-lbs
Solenoid contact post jamnut
6.5 SPEEDOMETER AND TACHOMETER: XR
1200X, Speedometer Installation
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer mounting
screw: XR 1200X
6.5 SPEEDOMETER AND TACHOMETER: XR
1200X, Trip Odometer Reset Switch Replace-
ment/XL 1200X
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer mounting
screw: XR 1200X
6-2 2013 Sportster Service: Electrical
NOTES
TORQUE VALUE
FASTENER
6.5 SPEEDOMETER AND TACHOMETER: XR
1200X, Tachometer Installation/XL 1200X
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer mounting
screw: XR 1200X
6.4 SPEEDOMETER: XL MODELS, Installation
0.9-1.4 Nm
8-12
in-lbs
Speedometer backplate fasteners: XL
models
6.10 STARTER, Installation
1.8-2.4 Nm
16-21
in-lbs
Starter motor oil line clamp fastener
6.10 STARTER, Installation
17.6-27.1 Nm
13-20 ft-lbs
Starter mounting bolt
6.10 STARTER, Installation
6.8-9.6 Nm
60-85
in-lbs
Starter positive terminal nut
6.10 STARTER, Solenoid
6.8-9.0 Nm
60-80
in-lbs
Starter ring terminal hex nut
6.24 ALTERNATOR, Assembly and Installa-
tion/Screw must be flush with plate. Do not exceed
torque specification.
6.3 Nm
56
in-lbs
Stator harness retainer screw
6.9 BATTERY TRAY, Installation
8.1-13.6 Nm
72-120
in-lbs
Stop lamp switch bracket screw
6.21 REAR STOP LAMP SWITCH, Replacement
14.9-18.9 Nm
132-168
in-lbs
Stop lamp switch to tee nut
6.19 REAR TURN SIGNALS, XL 883R/L
14.9-24.4 Nm
132-216
in-lbs
Strut cover screw
6.19 REAR TURN SIGNALS, XL 883N and XL
1200X/V
14.9-24.4 Nm
132-216
in-lbs
Strut cover screw
6.34 RIGHT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45
in-lbs
Switch housing screw
6.35 LEFT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45
in-lbs
Switch housing screw
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, Base Replacement: XL 883R/L
and XR 1200X
5.1-5.4 Nm
45-48
in-lbs
Tail lamp base mounting screw: XL
Models
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, Base Replacement: XL 883R/L
and XR 1200X
4.1-6.8 Nm
36-60
in-lbs
Tail lamp base mounting screw: XR
1200X
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, LED Tail Lamp: XL 1200C/C
ANV/CP/CA/CB
4.5-5.6 Nm
40-50
in-lbs
Tail lamp LED base fasteners: XL
1200C/C ANV/CP/CA/CB
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, LED Tail Lamp: XL 1200C/C
ANV/CP/CA/CB
2.3-2.8 Nm
20-25
in-lbs
Tail lamp LED screws: XL 1200C/C
ANV/CP/CA/CB
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, Bulb Replacement Except XL
1200C/C ANV/CP/CA/CB
2.3-2.7 Nm
20-24
in-lbs
Tail lamp lens screw
6.16 TAIL LAMP: ALL MODELS EXCEPT XL
883N/XL 1200X/V, Base Replacement: XL 883R/L
and XR 1200X
2.3-2.7 Nm
20-24
in-lbs
Tail lamp lens screw
6.18 FRONT TURN SIGNALS, All Except XL 1200X
10.8-16.3 Nm
96-144
in-lbs
Turn signal, front, ball head studs
6.18 FRONT TURN SIGNALS, All Except XL 1200X
10.8-13.6 Nm
96-120
in-lbs
Turn signal clamp, front, screw
6.19 REAR TURN SIGNALS, XR 1200X
3.4-4.5 Nm
30-40
in-lbs
Turn signal housing, rear, screws: XR
1200X
6.18 FRONT TURN SIGNALS, XL 1200X
16.3-21.7 Nm
12-16 ft-lbs
Turn signal housing to bracket: XL
1200X
6.19 REAR TURN SIGNALS, XL 883R/L
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount, rear,
fastener
6.19 REAR TURN SIGNALS, XL 883N and XL
1200X/V
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount, rear,
fastener
6.19 REAR TURN SIGNALS, XL 1200C/C
ANV/CP/CA/CB
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount, rear,
fastener
6.19 REAR TURN SIGNALS, XL 883R/L
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
6.19 REAR TURN SIGNALS, XL 883N and XL
1200X/V
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
2013 Sportster Service: Electrical 6-3
NOTES
TORQUE VALUE
FASTENER
6.19 REAR TURN SIGNALS, XL 1200C/C
ANV/CP/CA/CB
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
6.19 REAR TURN SIGNALS, XL 1200C/C
ANV/CP/CA/CB
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
6.23 VOLTAGE REGULATOR, Installation: XL
Models
4.1-6.8 Nm
36-60
in-lbs
Voltage regulator mounting screw
6.23 VOLTAGE REGULATOR, Installation: XR
1200X
4.1-6.8 Nm
36-60
in-lbs
Voltage regulator mounting screw
6.25 VEHICLE SPEED SENSOR (VSS), Installation
10.2-13.6 Nm
90-120
in-lbs
VSS screw
6-4 2013 Sportster Service: Electrical
6.2
SPECIFICATIONS: ELECTRICAL
SPECIFICATIONS
Table 6-1. Electrical: XL Models
SPECIFICATION
COMPONENT
Not adjustable
Ignition timing
12 V, 225 CCA, 12 Ah,
sealed and maintenance free
Battery
Single-phase, 30 A system
(357 W @ 13.5 V, 2000 rpm,
405 W max power @ 13.5 V)
Charging system
6R12
Spark plug type
12 mm
Spark plug size
0.97-1.09 mm
0.038-0.043 in
Spark plug gap
16.3-24.4 Nm
12-18 ft-lbs
Spark plug torque
Table 6-2. Electrical: XR 1200X
SPECIFICATION
COMPONENT
Not adjustable
Ignition timing
12 V, 225 CCA, 12 Ah,
sealed and maintenance free
Battery
Single-phase, 30 A system
(357 W @ 13.5 V, 2000 rpm,
405 W max power @ 13.5 V)
Charging system
10R12X
Spark plug type
12 mm
Spark plug size
0.81-0.97 mm
0.032-0.038 in
Spark plug gap
16.3-24.4 Nm
12-18 ft-lbs
Spark plug torque
Table 6-3. Ignition Coil Resistance
SECONDARY
PRIMARY
RESISTANCE
1500-2400 Ohm
0.3-0.7 Ohm
All Models
Table 6-4. Alternator
SPECIFICATION
ITEM
20-28 VAC per 1000 engine
rpm
AC voltage output
0.1-0.3 Ohm
Stator coil resistance
Table 6-5. Voltage Regulator
SPECIFICATION
ITEM
14.3-14.7 VDC
Voltage output @ 75 °F
32 A
Current @ 3600 rpm
Table 6-6. Fuses
AMP RATING
ITEM
30
Main fuse
15
Battery
15
Ignition
15
Lights
15
Accessories
15
Electronic Control Module
(ECM)
Table 6-7. Starter Specifications
STARTER DATA
3000 rpm (min) @ 11.5 V
Free speed
90 A (max) @ 11.5 V
Free current
200 A (max) @ 68 °F
Cranking current
8.0 ft-lbs (10.8 Nm) @ 2.4 V
Stall torque
Table 6-8. Starter Service Wear Limits
mm
in
ITEM
11.0
0.443
Brush length (minimum)
0.41
0.016
Commutator runout
28.98
1.141
Commutator diameter (minimum)
0.203
0.008
Commutator mica depth (minimum)
2013 Sportster Service: Electrical 6-5
6.3
FUSES AND RELAYS
GENERAL
The starter relay allows a relatively small amount of current
flowing through the starter button to control the large current
flow required to activate the starter solenoid.
See
. The electrical system relay/fuse block is located
in front of the battery under the left side cover. The relays and
fuses are mounted in the relay/fuse block. All fuses are rated
at 15 amperes.
MAIN FUSE
Removal
1.
Open left side cover. See
NOTE
Models with Sirens: Verify that fob is present and turn ignition
key to IGNITION before removing main fuse or disconnecting
battery.
2.
See
. Squeeze cover release latches (4)
together and pull fuse holder [5] (1) from protective cover
(3).
3.
See
. Grasp fuse holder (2) and pull main fuse
(1) straight out.
4.
Close left side cover.
NOTE
Always close left side cover if performing other procedures.
Failure to close cover will cause cosmetic damage.
Installation
1.
Open left side cover. See
2.
Verify ignition key is turned to OFF position.
3.
See
. Install main fuse (1) by lining up spade
terminals on fuse with sockets in fuse holder [5] (2). Press
fuse firmly into holder.
4.
See
. While holding protective cover (3) in place,
push fuse holder [5] (1) into cover until cover release
latches (4) snap into place.
5.
Close left side cover.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
6.
Turn ignition switch ON. Verify proper operation of elec-
trical system.
1
4
2
3
5
sm06671
1. Main fuse holder [5]
2. Battery strap
3. Protective cover
4. Cover release catches
5. Relay and fuse blocks
Figure 6-1. 30 A Main Fuse Location: All Models
1
2
sm06672
1. Main fuse
2. Fuse holder [5]
Figure 6-2. Removing/Installing Main Fuse
FUSES
1.
Open left side cover. See
.
2.
See
. Remove suspect fuse (3-7).
a.
Inspect fuse for damage. Always discard damaged
fuses.
b.
Replace fuse by pressing firmly into socket.
3.
Close left side cover.
6-6 2013 Sportster Service: Electrical
4.
Turn ignition switch ON. Verify operation of electrical
system.
RELAYS
1.
Open left side cover. See
Always use replacement fuses that are of the correct type
and amperage rating. Use of incorrect fuses can result in
damage to electrical systems. (00222a)
2.
See
. To unplug old relay (1 or 2), grasp body
of relay and with a gentle rocking motion, pull straight out
from relay/fuse block.
3.
To install
new
relay, line up spade terminals of relay with
sockets in relay/fuse block and push relay firmly into
sockets.
4.
Close left side cover.
5.
Verify operation of lighting system.
1
2
6
8
7
3
4
5
SM06661
1. System relay
2. Starter relay
3. Ignition fuse
4. Lights fuse
5. Accessory fuse
6. ECM fuse
7. Battery fuse
8. Spare fuse
Figure 6-3. Relay/Fuse Block (typical)
2013 Sportster Service: Electrical 6-7
6.4
SPEEDOMETER: XL MODELS
REMOVAL
NOTE
The speedometer has backlight LEDs that cannot be replaced.
If an LED fails, replace the entire unit.
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.
Remove reset switch boot from trip odometer reset switch
on speedometer housing back plate.
3.
Remove two screws and back plate.
4.
Unplug speedometer socket connector [39B] from back
of speedometer.
5.
Gently push out speedometer and front gasket.
NOTE
XL 1200X: This model does not have a back gasket.
6.
Inspect front and back gaskets, speedometer connector
[39] and wiring, trip odometer reset switch and wiring and
reset switch boot. Repair or replace as required.
INSTALLATION
TOOL NAME
PART NUMBER
CRIMPING TOOL
HD-45929
TORQUE VALUE
FASTENER
0.9-1.4 Nm
8-12
in-lbs
Speedometer backplate
fasteners: XL models
Reset Switch
1.
Push trip reset socket terminals out the front of the
speedometer socket connector half [39B].
2.
Cut off socket terminals. Pull faulty switch wires out of
connector.
3.
Push wires of a replacement switch through speedometer
connector (sockets 8, 11) and crimp
new
socket terminals
using CRIMPING TOOL (Part No. HD-45929).
4.
Draw terminal back into connector until terminal seats.
Speedometer
NOTES
•
XL 883L/N/R and XL 1200V and XL 1200CP/CB Models
with Mini Ape Handlebar: See
•
XL 1200X: See
•
XL 1200C/C ANV/CP/CA except XL 1200CP/CB Models
with Mini Ape Handlebar: See
1.
Install front gasket on speedometer.
2.
Threading speedometer harness and connector [39B]
through back gasket, install matching tabs of gasket to
locating keys in instrument housing/bracket.
NOTE
If necessary, lubricate rubber gaskets with alcohol or glass
cleaner.
3.
Orient face upright. Press speedometer into instrument
housing/bracket. Wiring must past between locating keys
and gasket and through cutout in speedometer back.
4.
Plug speedometer socket connector [39] into back of
speedometer.
5.
Push trip odometer reset switch through backplate. Thread
on reset switch boot.
6.
Hold backplate in place with reset switch in rectangular
boss in back of speedometer and vent hole at bottom.
Install fasteners. Tighten to 8-12
in-lbs
(0.9-1.4 Nm).
7.
Install main fuse.
6
8
5
9
3
7
11
10
4
2
1
sm06824
1. Speedometer
2. Front gasket
3. Instrument housing/bracket
4. Back gasket
5. Backplate
6. Reset switch boot
7. Trip odometer reset switch
8. Indicator lamp module
9. Speedometer harness connector [39B]
10. Instrument harness connector [20A]
11. Indicator lamp bezel
Figure 6-4. Speedometer Components: XL 883L/N/R, XL
1200V, XL 1200CP/CB Mini-Ape Handlebar
6-8 2013 Sportster Service: Electrical
5
7
6
10
8
4
1
2
3
9
sm06823
1. Speedometer
2. Front gasket
3. Instrument housing/bracket
4. Back plate
5. Reset switch boot
6. Trip odometer reset switch
7. Indicator lamp module
8. Speedometer harness connector [39B]
9. Instrument harness connector [20A]
10. Indicator lamp bezel
Figure 6-5. Speedometer Components: XL 1200X
11
2
4
7
5
3
6
9
10
8
1
sm07139
1. Speedometer
2. Gasket
3. Trip odometer reset switch
4. Reset switch boot
5. Instrument housing
6. Fastener
7. Indicator lamp bezel
8. Indicator lamp lens
9. Indicator lamp module
10. Instrument harness connector [20A]
11. Speedometer harness conector [39B]
Figure 6-6. Speedometer: XL 1200C/C ANV/CP/CA
2013 Sportster Service: Electrical 6-9
6.5
SPEEDOMETER AND TACHOMETER: XR 1200X
SPEEDOMETER REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
NOTE
This part cannot be repaired. Replace upon failure.
1.
Remove main fuse.
2.
See
. Remove reset switch boot (11).
3.
Remove screws (6) and back cover (5).
4.
Disconnect speedometer connector [39B] (8).
5.
Push out the speedometer (2) with gasket (3).
6.
Inspect gasket (3), speedometer connector [39B] (8), and
wiring. Repair or replace as required.
SPEEDOMETER INSTALLATION
TORQUE VALUE
FASTENER
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer
mounting screw: XR 1200X
1.
See
. Install gasket (3) on speedometer (2).
2.
Orient face upright and press speedometer (2) into
instrument housing/bracket (4).
3.
Install speedometer connector [39B] (8).
4.
Attach trip odometer reset switch (10) into squared boss
on back cover (5) and secure with reset switch boot (11).
5.
Place back cover over speedometer and tachometer while
positioning harness to avoid damage. Rotate speedometer
and tachometer as needed to align mounting holes. Install
screws (6). Tighten to 12-18
in-lbs
(1.4-2.0 Nm).
6.
Install main fuse.
5
8
11
1
9
4
2
10
13
7
6
3
12
sm05544a
1. Tachometer
2. Speedometer
3. Speedometer gasket
4. Instrument housing/bracket
5. Back cover
6. Screw
7. Indicator lamp module
8. Speedometer connector [39B]
9. Instrument harness connector [20A]
10. Trip odometer reset switch
11. Reset switch boot
12. Tachometer connector [108B]
13. Tachometer gasket
Figure 6-7. Instruments: XR 1200X
6-10 2013 Sportster Service: Electrical
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