Harley Davidson 2013 Sportster Models. Service Manual — page 20
3.
See
. Install the handlebar:
a.
Position handlebar on the lower handlebar camp.
b.
Adjust handlebar to the desired position.
c.
Place the upper handlebar clamp/speedometer
housing in position and thread four screws in place.
d.
Tighten the front screws first to 12-18 ft-lbs (16.3-24.4
Nm).
e.
Tighten the rear screws to 12-18 ft-lbs (16.3-24.4
Nm).
NOTES
•
Route the handlebar wiring harnesses.
•
Do not pinch the wiring harnesses.
4.
Install the riser cover and screws. Tighten to 8-12
in-lbs
(0.9-1.4 Nm).
1
4
2
3
sm03865
1. Lower clamp
2. Front screw (2) (tighten first)
3. Rear screw (2)
4. Upper clamp
Figure 2-190. Handlebar Riser: XL 1200C/C ANV
XL 1200CP
Pull Back:
See
. See
Installation, XL 1200C/C
ANV
.
Drag Bar:
See
. See
Installation, XL 1200C/C
ANV
.
Mini-Ape:
See
. See
Installation, All Models
except XL 1200C/C ANV
.
NOTE
See
. Rotate mini-ape handlebar 11 degrees (2)
rearward of the fork angle. Measure from a straight edge placed
on the fork bracket 2.96 in (75 mm) to the end of the straight
(1) (beginning of the last bend). This angle positions the
handgrips 15 in (381 mm) above seat height.
1
2
sm07468
1. 2.96 in (75.184 mm)
2. 11 degrees
Figure 2-191. XL 1200CP/CB Mini-Ape Handlebar Angle
XL 1200V
NOTE
See
. Rotate mini-ape handlebar 17 degrees (2)
rearward of the fork angle. Measure from a straight edge placed
on the fork bracket 3.72 in (94 mm) to the end of the straight
(1) (beginning of the last bend). This angle positions the center
of the handgrips 15 in (381 mm) above seat height.
2
1
sm07469
1. 3.72 in (94 mm)
2. 17 degrees
Figure 2-192. XL 1200V Handlebar Angle Domestic,
California and Canada Markets Only
All XL Models except XL 1200C/C ANV
1.
If lower handlebar clamps were removed, secure clamps
to upper fork bracket with bolts and washers. Finger tighten
2-136 2013 Sportster Service: Chassis
bolts only at this time. Route the wiring harnesses between
the lower handlebar clamps.
2.
Slide right side handlebar control housing and throttle
assembly onto right end of handlebar. Position handlebar
on lower handlebar clamps.
3.
Place upper handlebar clamp/instrument bracket in posi-
tion. Install four screws.
4.
See
. Adjust handlebar to desired position.
Tighten rear screws first, to 12-18 ft-lbs (16.3-24.4 Nm).
Then tighten front screws to 12-18 ft-lbs (16.3-24.4 Nm).
5.
Tighten lower handlebar riser bolts to 30-40 ft-lbs (40.7-
54.3 Nm).
1
2
3
4
5
sm03867
1. Lower clamp (2)
2. Cast-in spacer (2)
3. Rear screw (2) (tighten first)
4. Front screw (2)
5. Upper clamp
Figure 2-193. Handlebar Riser: XL Models except XL
1200C/C ANV
XR 1200X
1.
Slide right side handlebar control housing and throttle
assembly onto right end of handlebar. Position handlebar
on upper fork bracket.
2.
Place upper handlebar clamp in position. Install the rear
screws.
3.
Place instrument bracket in position. Install front screws
and washers.
4.
Adjust handlebar to desired position. Tighten rear screws
first, to 12-18 ft-lbs (16.3-24.4 Nm). Then tighten front
screws to 12-18 ft-lbs (16.3-24.4 Nm).
All Models
1.
Install front brake master cylinder assembly. See
2.8 FRONT BRAKE MASTER CYLINDER
2.
Install a
new
left hand grip. See
.
3.
Position left hand control and loosely install hand control
clamp screws. See
4.
Attach clutch control assembly to left side of handlebar.
5.
Tighten:
a.
Clutch lever handlebar clamp screw to 108-132
in-lbs
(12.2-14.9 Nm). See
.
b.
Left hand control clamp screws to 35-45
in-lbs
(4.0-
5.1 Nm).
c.
Right hand control clamp screws to 35-45
in-lbs
(4.0-
5.1 Nm).
6.
Install four
new
wiring harness retainers around handlebar
wiring harnesses. Push retainers into holes in handlebar.
7.
Install main fuse.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
8.
Verify the following:
a.
Clutch cable adjustment/operation.
b.
Proper throttle cable operation.
c.
All electrical switch functions.
d.
Proper brake operation and stop lamp function.
LEFT HAND GRIP
Removal
Slice the hand grip open with a sharp knife. Peel the hand grip
open to remove.
Installation
1.
Rough the left grip end of the handlebar with emery cloth.
2.
Clean the grip end with acetone.
3.
Apply LOCTITE 770 PRISM PRIMER to the inside of a
new
hand grip. Remove any excess primer with a clean
cloth. Wait two minutes for the primer to set.
4.
Apply LOCTITE 411 PRISM INSTANT ADHESIVE to the
inside of the
new
hand grip.
NOTE
LOCTITE 411 PRISM INSTANT ADHESIVE will set in four
minutes and cure in 24 hours.
5.
Install the
new
hand grip with a twisting motion.
2013 Sportster Service: Chassis 2-137
2.31
FRONT FENDER
ALL MODELS
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Fender to forks, front: XL
except XL 1200X
3.4-4.7 Nm
30-42
in-lbs
Fender to fork brace, front: XL
1200X
25-30 Nm
18-22 ft-lbs
Fork brace to forks: XL 1200X
4.1-6.8 Nm
30-60
in-lbs
Fender to bracket, front: XR
1200X
21-25 Nm
15-19 ft-lbs
Fender bracket to forks, front:
XR 1200X
See
. Install and tighten in a cross pattern to
specification. Refer to
2
3
5
4
1
1
sm06808
Figure 2-194. Front Fenders
2-138 2013 Sportster Service: Chassis
Table 2-27. Front Fender Fastener Torque Values
TORQUE
FASTENER
CALLOUT
MODEL
96-156
in-lbs
(10.9-17.6 Nm)
Fender to forks, front: XL except XL 1200X
1
XL models
(fasteners with locknuts)
(except XL 1200X)
30-42
in-lbs
(3.4-4.7 Nm)
Fender to fork brace, front: XL 1200X
2
XL 1200X
(tighten in cross pattern)
18-22 ft-lbs (25-30 Nm)
Fork brace to forks, front: XL 1200X
3
30-60
in-lbs
(4.1-6.8 Nm)
Fender to bracket, front: XR 1200X
4
XR 1200X
(fasteners with locknuts)
15-19 ft-lbs (21-25 Nm)
Front fender bracket to forks: XR 1200X
5
2013 Sportster Service: Chassis 2-139
2.32
FRONT LICENSE PLATE: INDIA MODELS
FRONT LICENSE PLATE: XL MODELS
(INDIA)
TORQUE VALUE
FASTENER
1.1-1.7 Nm
10-15
in-lbs
License plate fasteners, front:
XL 883L/N/R (India)
1.1-1.7 Nm
10-15
in-lbs
License plate fasteners, front:
XL 1200X/C/C ANV (India)
XL 883L/N/R
1.
See
. Install P-clamps (6) on fork tubes.
2.
Install license plate to P-clamps and secure fasteners (4),
washers (3) and nuts (5).
a.
XL 883N/R
(1)
b.
XL 883L,
(2)
3.
Tighten to 10-15
in-lbs
(1.1-1.7 Nm).
1
3
4
5
6
2
pd00379a
1. License plate: XL 883N/R
2. License plate: XL 883L
3. Washer (4)
4. Fastener (2)
5. Nut (2)
6. P-clamp (2)
Figure 2-195. License Plate Mount: XL 883L/N/R (India)
XL 1200X/C/C ANV
1.
See
. Install license plate (1) to license plate
bracket and secure with fasteners (3), washers (2) and
nuts (4).
2.
Tighten to 10-15
in-lbs
(1.1-1.7 Nm).
1
2
3
4
pd00381
1. License plate
2. Washer (4)
3. Fastener (2)
4. Nut (2)
Figure 2-196. License Plate Mount: XL 1200X/C/C ANV
(India)
2-140 2013 Sportster Service: Chassis
2.33
REAR FENDER: ALL XL MODELS EXCEPT XL
883N, XL 1200X/V
XL 883R/L
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Seat post bolt
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk locknut
14.9-24.4 Nm
132-216
in-lbs
Fender, rear, mounting
fastener
Removal
1.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
See
. Disconnect the rear lighting connector
[7] (2) housings.
4.
Access fender hardware.
a.
Remove lower shock bolts.
b.
Raise motorcycle to lower rear wheel.
5.
Remove the tail lamp assembly.
a.
Remove the tail lamp lens and bulb. See
LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V,
Base Replacement: XL 883R/L and XR 1200X
.
b.
See
. Unplug left [19] (1) and right [18]
(2) turn signal connectors from rear lighting circuit
board.
c.
Pull turn signal wiring harnesses thru holes in tail lamp
base and rear fender.
d.
Disengage turn signal wiring harnesses from wire
retention brackets.
6.
See
. Remove rear turn signal stalk locknuts
(1) from inside rear fender on both sides.
a.
See
. Support fender and remove front
strut cover fastener (4) with washer (3) and locknut
(1), and rear strut cover fastener (4) with washer (3)
and clip nut (5) on both sides.
b.
Remove rear fender strut covers with attached turn
signal assemblies.
c.
Remove bolt (11), seat post (7) and washer (8) to
detach top of fender from frame cross member tab.
d.
Carefully remove rear fender with attached license
plate bracket, tail lamp base and wire harness.
sm07144
Figure 2-197. Rear Lighting Connector [7]
1
3
4
2
5
sm06776
1. Left turn signal connector [19]
2. Right turn signal connector [18]
3. Rear lighting power connector [94]
4. Tail lamp connector [93]
5. Screw with washer
Figure 2-198. Tail Lamp Housing
2013 Sportster Service: Chassis 2-141
2
3
6
7
4
5
1
SM01219a
1. Rear turn signal stalk nut (2)
2. Forward fender support screw with washer (2)
3. Aft fender support screw with washer (2)
4. Forward fender support nut (2)
5. Aft fender support nut plate (2)
6. Wire retention bracket
7. Rear lighting wiring harness and conduit
Figure 2-199. Rear Fender, Strut Cover and Turn Signal
Lamp Assembly
1
8
9
4
1
6
7
5
3
2
3
10
11
sm07142
1. Locknut
2. Rear strut cover fastener
3. Washer
4. Front strut cover fastener
5. Clip nut
6. Inner fender brace
7. Seat post
8. Washer
9. Tee spacer
10. Grommet
11. Bolt
Figure 2-200. Rear Fender Assembly: XL 883R/L
Installation
1.
Carefully install rear fender onto motorcycle.
2.
See
. Align holes in fender with those in struts.
Support fender and install fasteners (4, 2) through fender
struts and fender to hold fender in place.
3.
Route rear lighting harness connector [7B] between frame
cross member and top of oil tank.
4.
Connect housings [7].
5.
Secure front of fender with bolt (11), washer (8) and seat
post (7). Finger-tighten.
6.
H-DSSS equipped models:
Make sure antenna harness
is not pinched between fender and frame crossmember.
7.
Remove fasteners (4, 2) and install fender strut cover with
attached turn signal assembly to fender strut. Push turn
signal wiring harness through openings in strut and fender.
8.
Install locknut (1) onto turn signal stalk from inside fender.
Finger-tighten.
9.
Secure fender to strut with fasteners (4), washer (3) and
locknut (1) in forward mounting hole. Install fastener (2),
washer (3) and clip nut (5) in aft mounting hole. Finger-
tighten.
2-142 2013 Sportster Service: Chassis
10. In sequence, tighten all fender mounting hardware:
a.
Tighten bolt and seat post to 96-156
in-lbs
(10.9-17.6
Nm).
b.
Tighten turn signal stalk locknuts to 132-216
in-lbs
(14.9-24.4 Nm).
c.
Tighten fender mounting fasteners to 132-216
in-lbs
(14.9-24.4 Nm).
11. Install the tail lamp assembly.
a.
Route turn signal wiring harnesses through the wire
retention brackets.
b.
Pull turn signal wiring harnesses through holes in rear
fender and tail lamp base.
c.
See
. Connect tail lamp connector [94]
(3) and left [19] (1) and right [18] (2) turn signal con-
nectors.
d.
Install the tail lamp lens and bulb. See
LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V,
Base Replacement: XL 883R/L and XR 1200X
.
12. Install main fuse.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
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)
13. Install seat.
14. Verify license plate lamp, tail lamp, stop lamp and turn
signals.
XL 1200C/C ANV/CP/CA/CB
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Seat post bolt
10.9-17.6 Nm
96-156
in-lbs
Turn signal stalk locknut
10.9-17.6 Nm
96-156
in-lbs
Fender, rear, mounting
fastener
Removal
1.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
See
. Disconnect the right [18] (3) and left
[19] (4) turn signal connectors and the tail lamp connector
[40] (2).
4.
Remove the lower shock bolts and lower the rear wheel
to access the fender hardware.
5.
See
. Route the turn signal wire harness
through the openings (4) in the fender and from the
retention bracket (3).
6.
See
. Remove rear turn signal stalk nuts (1)
from inside rear fender on both sides.
7.
Support the fender and remove the front (4) and rear (2)
fender fasteners with washers (3) and strut covers with
attached turn signal assemblies from rear fender struts.
8.
Remove bolt (11), seat post (7) and flat washer (8) to
detach top of rear fender from frame cross member tab.
9.
Carefully remove rear fender from motorcycle.
1
3
4
2
sm07136
1. Main harness connector [7]
2. Tail lamp connector [40]
3. RH turn signal connector [18]
4. LH turn signal connector [19]
Figure 2-201. Turn Signal Wire Harness: XL 1200C/C
ANV/CP/CA/CB
2013 Sportster Service: Chassis 2-143
1
3
2
4
1. Fender brace
2. Retention clip
3. Retention bracket
4. Fender opening
Figure 2-202. Inner Rear Fender: XL 1200C/C ANV/CP
3
2
7
8
5
11
6
1
1
3
4
9
12
10
13
sm07143
1. Locknut
2. Rear strut cover fastener
3. Washer
4. Front strut cover fastener
5. Clip nut
6. Inner fender brace
7. Seat post
8. Washer
9. Tee spacer
10. Grommet
11. Bolt
12. Subharness
13. Wire retention bracket (2)
Figure 2-203. Rear Fender Assembly: XL 1200C/C ANV/CP
Installation
1.
Install rear fender onto motorcycle. Align holes in fender
with those in struts. Temporarily install screws to hold
fender in place.
2.
Route tail lamp harness connector between frame cross
member and top of oil tank. Connect tail lamp housings
[40].
3.
See
. Secure front of fender with bolt (11),
washer (8) and seat post (7). Finger-tighten.
4.
H-DSSS equipped models:
Make sure antenna harness
is not pinched between fender and frame crossmember.
5.
Remove bolts from right side of fender. Install fender strut
cover with attached turn signal assembly to fender strut
with the locknut (1).
6.
Secure fender to strut with fasteners (4), washer (3) and
locknut (1) in forward mounting hole. Install fastener (2),
washer (3) and clip nut (5) in aft mounting hole. Finger-
tighten screws only at this time.
7.
Push turn signal wiring harness through openings in strut
and fender. Install nut onto turn signal stalk from inside
fender. Finger-tighten.
8.
Now tighten all fender mounting hardware in the following
sequence:
a.
Tighten bolt (11) and seat post (7) to 96-156
in-lbs
(10.9-17.6 Nm).
b.
Tighten turn signal stalk nuts (1) to 96-156
in-lbs
(10.9-17.6 Nm).
c.
Tighten fasteners (2, 4) to 96-156
in-lbs
(10.9-17.6
Nm).
9.
Install the lower lower shock bolts and lower the rear
wheel.
10. See
. Connect the right [18] (3) and left [19]
(4) turn signal connectors and the tail lamp connector [40]
(2).
11. Install main fuse.
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)
12. Install seat.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
13. Verify turn signals, tail lamp, and stop lamp.
FENDER PREPARATION
Tail Lamp Assembly
XL 883R/L:
Replace the tail lamp. See
MODELS EXCEPT XL 883N/XL 1200X/V, Base Replacement:
XL 883R/L and XR 1200X
.
XL 883N and XL 1200X/V:
The tail lamps are the rear turn
signals.
XL 1200C/C ANV/CP/CA/CB:
Replace LED tail lamp assembly.
See
6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL
1200X/V, LED Tail Lamp: XL 1200C/C ANV/CP/CA/CB
.
2-144 2013 Sportster Service: Chassis
License Plate Lamp Module: XL 883N and
XL 1200X/V
Replace the license plate lamp module. See
PLATE LAMP MODULE: XL 883N, XL 1200X/V
Seat Nut
Remove the C-clip and the seat nut. Replace with a
new
seat
nut kit.
Fender Extension
1.
See
. Drill out rivets (1) securing rear fender
extension (2) to fender with a 1/4 drill bit.
2.
Rivet fender extension to fender backed by a washer (3).
Wire Harness with Conduit
1.
Protect fender. Clean inside of fender with a mixture of
alcohol and water. Allow to air-dry.
2.
Position
new
wire harness and conduit inside fender in
same location. Insert end of wiring harness with D plug
through D hole in front of fender. Insert plug.
3.
Slide conduit toward D plug as far as it will go. Insert other
end of wiring harness through housing hole in rear of
fender.
4.
Remove adhesive tape backing from conduit and press
conduit in place along right side curve of fender.
Wire Retention Bracket
1.
See
. Drill out rivets (4) securing wire retention
brackets (5) with a 1/4 in drill.
2.
Rivet wire retention brackets to fender.
3
1
2
5
4
sm07147a
1. Rivet
2. Extension
3. Washer
4. Rivet
5. Wire retention bracket
Figure 2-204. Fender Extension
LICENSE PLATE BRACKET: XL 883R/L
TORQUE VALUE
FASTENER
2.3-2.8 Nm
20-25
in-lbs
License plate support bracket
screws
2.3-2.8 Nm
20-25
in-lbs
License plate bolt
Removal
1.
See
. Loosen the keps nut and remove the
license plate.
2.
Remove the keps nut, washer and bolt to remove the
clamp and the bracket.
3.
Remove the three screws to remove the support bracket
from the fender.
Installation
1.
Mount the support bracket on the fender with the screws.
2.
Fit the fender brace to the middle screw.
3.
Secure with washers and nuts. Tighten the screws to 20-25
in-lbs
(2.3-2.8 Nm).
4.
Assemble the bracket and the clamp to the support bracket
with the bolt, washer and keps nut.
5.
Install the license plate. Tighten the keps nut to 20-25
in-lbs
(2.3-2.8 Nm).
2013 Sportster Service: Chassis 2-145
8
4
6
2
3
7
1
9
5
sm07141
1. Refector
2. Bracket
3. Clamp
4. Support
5. Washer
6. Keps nut
7. Fastener
8. Screw
9. Nut
Figure 2-205. License Plate Bracket: XL Models except XL
883N, XL 1200X/C/CP
LICENSE PLATE BRACKET: XL 1200C/C
ANV/CP/CA/CB
TORQUE VALUE
FASTENER
2.3-2.8 Nm
20-25
in-lbs
License plate bracket, rear,
fasteners: XL 1200C/C
ANV/CP/CA/CB
2.3-2.8 Nm
20-25
in-lbs
License plate, rear, keps nut,
XL 1200C/C ANV/CP/CA/CB
1.
See
. Disassemble the upper license plate
bracket bolt (4), washer (5) and keps nut (6).
2.
Remove the two fasteners (2) from the tail lamp base to
remove the lower license plate bracket (1).
3.
Install the lower bracket and fasteners. Tighten to 20-25
in-lbs
(2.3-2.8 Nm).
4.
Install the tail lamp. See
EXCEPT XL 883N/XL 1200X/V, LED Tail Lamp: XL
1200C/C ANV/CP/CA/CB
5.
Assemble the upper bracket (3) with bolt (4), washer (5)
and keps nut (6).
6.
Install the license plate and tighten the keps nut to 20-25
in-lbs
(2.3-2.8 Nm).
3
2
6
5
4
1
sm07132a
1. Lower bracket
2. Fastener
3. Upper bracket
4. Bolt
5. Washer
6. Keps nut
Figure 2-206. License Plate Bracket
2-146 2013 Sportster Service: Chassis
2.34
REAR FENDER AND LICENSE PLATE BRACKET:
XL 883N, XL 1200X/V
GENERAL
Certain XL 883N and XL 1200X/V models have a side-mount
license plate bracket. This bracket includes a license plate
lamp module.
NOTE
Due to local regulations, this side mount license plate bracket
may not be offered in all markets.
Certain models do not have a rear fender-mounted tail lamp
and stop lamp. Instead, the rear turn signals also function as
tail lamps and stop lamps and are controlled by a rear lighting
converter module located under the seat.
For instructions on replacing the rear lighting converter module,
see
6.20 REAR LIGHTING CONVERTER MODULE: XL 883N,
NOTES
•
XL 883N/XL 1200X models sold in the international market
are equipped with a center mounted license plate bracket
that has a license plate lamp assembly.
•
XL 883N/XL 1200X models sold in the international market
are not equipped with a rear lighting converter module.
LED assemblies in the rear turn signal housings serve as
the stop lamp, tail lamp and turn signals.
REMOVAL AND DISASSEMBLY
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.
Position motorcycle upright on lift.
3.
Remove seat.
NOTE
For this procedure it will not be necessary to remove the rear
wheel.
4.
Raise motorcycle to remove pressure on the shock bolts.
5.
Remove
lower
shock
bolts.
See
.
6.
Using jack, raise motorcycle in order to gain clearance
between rear wheel and fender.
7.
See
. Unplug license plate lamp connector
(4) [40]. Unplug right rear lighting harness connector (2)
[18]. This connector is identified by a brown band on the
harness near the connector. Unplug left rear harness
connector (3) [19].
2
3
4
5
6
1
8
7
9
sm06682
1. Antenna [209] (H-DSSS equipped vehicles only)
2. Right rear lighting harness connector [18]
3. Left rear lighting harness connector [19]
4. License plate lamp harness [40]
5. Main wiring harness connector [7]
6. Engine harness connector [145]
7. Flat washer
8. Seat post
9. Frame crossmember tab
Figure 2-207. Rear Lighting Harness Connectors: XL 883N,
XL 1200X/V
8.
See
. Carefully pull both rear lighting har-
nesses (2, 3) and license plate lamp harness (6) through
feed-through holes (4, 5) in rear fender.
9.
Remove both rear lighting harnesses and license plate
lamp harness from fender harness clips (1).
10. See
. Remove left rear lighting harness (5)
from harness clips (2) on lower side of bracket on left side
of fender. Repeat this step for right side of fender.
11. See
. Remove rear turn signal stalk nuts (6)
from inside rear fender on both sides.
12. Remove forward fender support screw with washer (2)
and nut (4), and aft fender support screw with washer (3)
and nut plate (5) (domestic only) on both sides.
13. Remove screw with washer (9) and rear fender brace (7).
14.
HDI Models:
Remove license plate lamp module harness
from upper harness clips on bracket inside fender (left
side). Separate license plate bracket from rear fender
brace.
15. Remove rear fender strut covers (1) with attached turn
signal assemblies from rear fender struts. Carefully pull
turn signal wiring harnesses through holes in rear fender
and strut as each strut cover is removed.
2013 Sportster Service: Chassis 2-147
2
1
4
6
3
1
5
sm01172a
1. Harness bracket (2)
2. Right rear lighting harness
3. Left rear lighting harness
4. Right feed-through hole
5. Left feed-through hole
6. License plate lamp harness
Figure 2-208. Lighting Harnesses and Harness Brackets:
XL 883N, XL 1200X/V
1
4
3
5
7
6
2
sm01222
1. Upper license plate bracket harness clip (5)
2. Lower license plate bracket harness clip (3)
3. Harness channel
4. License plate lamp harness
5. Left rear lighting harness
6. Screw (2)
7. License plate lamp module
Figure 2-209. Removing/Installing License Plate Lamp
Module (domestic only)
9
8
1
2
4
6
5
7
3
sm03612a
1. Rear fender strut cover
2. Forward fender support screw with washer (2)
3. Aft fender support screw with washer (2)
4. Forward fender support nut (2)
5. Aft fender support nut plate (2)
6. Rear turn signal stalk nut (2)
7. Rear fender brace
8. Fender seat nut kit (2)
9. Screw with washer
Figure 2-210. Rear Fender, Strut Cover and Turn Signal
Lamp Assembly (domestic shown)
16. Place a clean shop towel between each fender strut and
fender to protect paint.
17. Have an assistant hold rear fender in place. See
. Remove seat post (1), washer (2) and screw
(5). Remove rear fender from vehicle, being careful not to
damage paint. Lay rear fender on a soft, clean surface.
18.
Domestic Models:
Remove convertible side mount license
plate bracket from rear fender.
a.
See
. Remove license plate lamp module
harness from upper harness clips (1) and harness
channel (3) in license plate bracket. Remove two
screws (6) and license plate lamp module (7).
b.
See
. Carefully drill out two pop rivets
(3) securing license plate bracket assembly (2) to left
side of fender.
19. See
. If rear fender is being replaced, do the
following:
a.
Remove fender seat nut kit (8).
b.
Carefully drill out pop rivets securing rear fender
extension to old fender with a 1/4-in (6.35 mm) dia-
meter drill bit.
c.
Set nut kit and fender extension aside for now.
2-148 2013 Sportster Service: Chassis
2
3
5
4
1
sm03611
1. Seat post
2. Washer
3. Fender mounting tab
4. Grommet
5. Screw
Figure 2-211. Seat Post/Rear Fender Mount Hardware
1
3
3
2
2
1
sm01223
1. Rear fender
2. License plate bracket assembly
3. Pop rivet (2)
Figure 2-212. Removing/Installing License Plate Bracket
Assembly (domestic)
ASSEMBLY AND INSTALLATION
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Seat post bolt
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk locknut
2.3-2.8 Nm
20-25
in-lbs
Fender brace, rear, screw
14.9-24.4 Nm
132-216
in-lbs
Fender support, rear, screw
1.
See
. If
new
rear fender is being installed, do
the following:
a.
Install fender seat nut kit (8).
b.
Rivet rear fender extension to fender.
2013 Sportster Service: Chassis 2-149
2.
DOM Models:
Install convertible side mount license plate
bracket on fender.
a.
See
. Position license plate bracket
assembly (2) against inside of rear fender (1) on left
side. Line up holes in bracket with holes in fender and
secure bracket to fender with two
new
pop rivets (3).
b.
See
. Install license plate lamp module
(7) on to license plate bracket. Secure with two screws
(6). Feed license plate lamp harness (4) up through
harness channel (3). Insert harness into upper license
plate bracket harness clips (1).
3.
Place clean shop towels over fender struts. With the aid
of an assistant, carefully install rear fender onto vehicle.
4.
See
. With assistant holding rear fender in
place, install screw (5) through fender and frame tab.
Install washer (2) on screw. Thread seat post (1) onto
screw. Finger-tighten seat post.
5.
H-DSSS:
Make sure antenna harness feeds up between
oil tank and fender on right side of vehicle and is not
pinched between fender and frame crossmember.
6.
Remove shop towels from fender struts.
7.
See
. Install fender strut covers (1) with
attached turn signal lamp assemblies. Carefully feed each
turn signal harness through appropriate hole in fender
strut and fender as you install each strut cover.
8.
Thread nut (6) onto each rear turn signal stalk finger-tight.
Install two forward fender support screws with washers
(2). Thread nut (4) onto each screw finger-tight.
9.
HDI Models:
Hook tab of license plate bracket into slot in
rear fender brace.
10. Place rear fender brace (7) in position under fender and
secure with screw and washer (9) finger-tight. Install two
aft fender support screws with washers (3).
a.
HDI Models:
Thread each mounting screw through
rear fender brace, into threaded inserts in license
plate bracket. Install finger-tight. Make sure threaded
inserts in license plate bracket fit into holes in rear
fender brace.
b.
DOM Models:
See
. Install nut plate (2)
on each mounting screw (5) finger-tight.
NOTE
DOM Models: see
. Make certain that tab (3) on
each nut plate (2) fits into slot (4) in fender brace (1) when
securing nut plate with rearmost fender mounting screw (5).
11. Now tighten all fender mounting hardware in the following
sequence:
a.
See
. Tighten screw (5) and seat post
(1) to 96-156
in-lbs
(10.9-17.6 Nm).
b.
See
. Tighten left and right turn signal
stalk nuts (6) to 132-216
in-lbs
(14.9-24.4 Nm).
c.
Tighten rear fender brace screw (9) to 20-25
in-lbs
(2.3-2.8 Nm).
d.
Tighten forward and aft fender support screws (2, 3)
on both sides of fender to 132-216
in-lbs
(14.9-24.4
Nm).
12. See
. Install left rear lighting harness (3) and
license plate lamp harness (6) into fender harness clip (1)
on left side of fender. Install right rear lighting harness (2)
into fender harness clip on right side of fender.
13. Carefully feed both rear lighting harnesses and license
plate lamp harness through feed-through holes (4, 5) in
rear fender.
14. Plug in license plate lamp connector [40]. Plug in left rear
lighting harness connector [18].
15. Plug in right rear lighting harness connector [19]. This
connector is identified by a brown band on the harness
near the connector.
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)
16. Install seat.
17. Lower motorcycle and install lower shock bolts. See
2.24 SHOCK ABSORBERS, Installation
.
18. Install main fuse.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
19. Turn ignition switch ON. Verify all rear lighting is operating
properly: license plate lamp, tail lamps, stop lamps and
turn signals.
2-150 2013 Sportster Service: Chassis
1
3
4
5
2
sm01224
1. Rear fender brace
2. Nut plate (2)
3. Tab
4. Slot
5. Mounting screw (2)
Figure 2-213. Rear Fender Nut Plate (Domestic Only)
2013 Sportster Service: Chassis 2-151
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст