Harley Davidson 2013 Sportster Models. Service Manual — page 21
2.35
REAR FENDER: XR 1200X
REMOVAL
1.
Remove rider's seat and passenger pillion.
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
. Remove three bolts and washers (1).
Remove two bolts (2) and retainers (3). Lift tail section (4)
off from motorcycle.
4.
Remove screw (5). Rotate inner fender (6) down and
release tabs (7) from notches in frame.
5.
Disconnect ECM connector and remove inner fender and
ECM as an assembly. Remove ECM from inner fender if
necessary.
INSTALLATION
TORQUE VALUE
FASTENER
4.1-6.8 Nm
36-60
in-lbs
Passenger pillion retainer post
screw: XR 1200X
8.1-13.6 Nm
72-120
in-lbs
Fender, inner screw: XR
1200X
8.1-13.6 Nm
72-120
in-lbs
Tailsection bolts: XR 1200X
1.
See
. If removed, install passenger pillion
retainer post (9). Tighten screw (8) to 36-60
in-lbs
(4.1-
6.8 Nm).
2.
If removed, install ECM on inner fender.
3.
While holding inner fender/ECM assembly in place, con-
nect ECM connector.
4.
Verify that the tabs (7) are located in notches in frame and
secure inner fender with screw (5). Tighten to 72-120
in-lbs
(8.1-13.6 Nm).
NOTE
Washers and retainers (3) are installed with shoulder down.
5.
Install tailsection (4) and secure with bolts, washers, and
seat retainers. Tighten bolts to 72-120
in-lbs
(8.1-13.6
Nm).
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)
6.
Install passenger pillion and rider's seat.
7.
Install main fuse.
1
1
9
2
3
1
4
8
7
6
5
sm05333
1. Bolt and washer, short (3)
2. Bolt, long (2)
3. Seat retainer (2)
4. Tail section
5. Screw, inner fender
6. Inner fender
7. Tabs
8. Pillion retainer post screw
9. Passenger pillion retainer post
Figure 2-214. Rear Fender: XR 1200X
2-152 2013 Sportster Service: Chassis
2.36
SAREE GUARD: INDIA MODELS
SAREE GUARD: XL 883R, XL 1200C/C ANV
(INDIA)
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Strut cover fastener
10.9-17.6 Nm
96-156
in-lbs
Turn signal stalk locknut
10.9-17.6 Nm
96-156
in-lbs
Strut cover fastener
21.7-27.1 Nm
16-20 ft-lbs
Saree guard, left-front, pas-
senger footrest support
bracket fastener
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
Right, Left-Rear
1.
Remove the rear strut cover. See
ALL XL MODELS EXCEPT XL 883N, XL 1200X/V, XL
883R/L
.
2.
See
. Remove the saree guard (1).
3.
Install the saree guard.
a.
Fit the saree guard to the fender strut.
b.
Thread the turn signal connector and wire harness
through the notch in the saree guard and the hole in
the fender.
c.
Install the strut cover.
d.
Verify the installation of the rear fastener clip nut (6).
e.
Install the front and rear strut cover fasteners (2) and
washers (3).
f.
Install the front fastener locknut (4) and the turn signal
stalk locknut (5).
4.
Tighten the fasteners:
a.
Front strut cover fastener to 96-156
in-lbs
(10.9-17.6
Nm).
b.
Turn signal stalk locknut to 96-156
in-lbs
(10.9-17.6
Nm).
c.
Rear strut cover fastener to 96-156
in-lbs
(10.9-17.6
Nm).
5.
Complete the strut cover installation. See
FENDER: ALL XL MODELS EXCEPT XL 883N, XL
1200X/V, XL 883R/L
.
3
2
6
1
4
5
sm07532b
1. Right saree guard
2. Strut cover fastener (2)
3. Washer (2)
4. Strut cover fastener locknut (2)
5. Turn signal stalk locknut (2)
6. Clip nut (2)
Figure 2-215. Right, Left-Rear Saree Guard
Left-Front
1.
Remove the left passenger footrest. See
.
2.
Remove the left upper rear shock absorber fastener and
washer. See
.
3.
See
. Remove the saree guard (1).
a.
Remove the stud cover (2).
b.
Remove the screw (3), the two washers (4) and the
flange nut (5).
NOTE
Apply 2-3 drops of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to the threads of the
shock absorber fastener.
4.
Install the saree guard.
a.
Fit the saree guard to the footrest bracket and the
shock mount.
b.
Install the screw, washers and the flange nut.
c.
Install the shock stud cover.
d.
Install the shock absorber fastener and washer.
5.
Tighten the passenger footrest support bracket fastener
to 16-20 ft-lbs (21.7-27.1 Nm).
6.
Tighten the shock absorber mounting bolt to 45-50 ft-lbs
(61-68 Nm).
7.
Install the passenger footrest. See
.
2013 Sportster Service: Chassis 2-153
3
4
5
2
1
sm07530
1. Left-front saree guard
2. Shock stud cover
3. Fastener
4. Washer
5. Flange nut
Figure 2-216. Left-Front Saree Guard
2-154 2013 Sportster Service: Chassis
2.37
REAR LICENSE PLATE: INDIA MODELS
REAR LICENSE PLATE: XL MODELS (INDIA)
TORQUE VALUE
FASTENER
1.1-1.7 Nm
10-15
in-lbs
License plate screw: XL
883L/R (India)
1.1-1.7 Nm
10-15
in-lbs
License plate screw: XL 883N,
XL 1200X (India)
XL 883L/R, XL 1200C/C ANV
1.
See
. Assemble the screws (1), washers (2)
the license plate and the nuts (3) to the license plate
bracket.
2.
Tighten to 10-15
in-lbs
(1.1-1.7 Nm).
2
2
3
1
pd00430
1. Screw (2)
2. Washer (4)
3. Nut (2)
Figure 2-217. License Plate Bracket: XL 883L/R (India)
(shown)
XL 883N, XL 1200X
1.
See
. Move the reflector bracket (1) to the
lowest mounting holes.
2.
Assemble the screws (2), washers (3), license plate and
nuts (4) to the license plate bracket.
3.
Tighten to 10-15
in-lbs
(1.1-1.7 Nm).
2
3
3
4
1
pd00431
1. Reflector bracket
2. Screw (2)
3. Washer (4)
4. Nut (2)
Figure 2-218. License Plate Bracket: XL 883N (India)
(shown)
2013 Sportster Service: Chassis 2-155
2.38
JIFFY STAND
REMOVAL
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)
1.
Position motorcycle upright on a suitable lift.
NOTE
Remove stop to release spring tension.
2.
See
. Remove stop (1).
3.
Retract leg (2).
4.
Remove pretzel clip (3). Discard pretzel clip.
Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring, attached
components and/or hand tools to fly out which could result
in death or serious injury. (00477c)
5.
Hold leg in retracted position. Withdraw clevis pin (4) until
it disengages from upper pivot hole of yoke.
6.
Use pliers to detach spring (5) from the frame mounted
anchor pin. Unhook end of spring from leg.
7.
Remove clevis pin from lower pivot hole of yoke.
8.
Remove upper and lower bushings (6).
9.
Remove bumper (7) if required.
10. Remove JSS if equipped. See
SENSOR (JSS): INTERNATIONAL MODELS
.
3
6
4
7
1
5
2
6
sm07551b
1. Stop
2. Leg
3. Pretzel clip
4. Clevis pin
5. Spring
6. Bushing (2)
7. Bumper
Figure 2-219. Jiffy Stand
CLEANING AND LUBRICATION
1.
Clean the jiffy stand components, the frame-mounted yoke
and the anchor pin.
2.
See
. Apply ANTI-SEIZE LUBRICANT to the
leg pivot holes in the yoke (1), the groove of the anchor
pin (2) and the OD of the clevis pin.
3.
Coat the ramp (3) of the yoke with ANTI-SEIZE LUB-
RICANT.
1
2
3
sm06944d
1. Pivot holes
2. Anchor pin groove
3. Ramp
Figure 2-220. Lubrication Points
2-156 2013 Sportster Service: Chassis
INSTALLATION
Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring, attached
components and/or hand tools to fly out which could result
in death or serious injury. (00477c)
1.
If required, install the JSS. See
SENSOR (JSS): INTERNATIONAL MODELS
.
2.
Press in a
new
rubber bumper.
NOTE
Face open ends of spring hooks toward centerline of vehicle.
3.
See
. Install spring.
a.
Hook spring into spring mounting hole (2) on leg.
b.
Hook spring over frame mounted anchor pin (1).
4.
Install bushing onto clevis pin with shoulder of bushing
facing head of clevis pin.
5.
Hold leg in its retracted position. Insert clevis pin halfway
up through yoke and pivot hole of leg.
NOTE
Make certain that shank of lower bushing fits inside lower pivot
hole in yoke.
6.
Push clevis pin through slotted upper hole in yoke.
7.
Install upper bushing with shoulder facing up against upper
surface of yoke.
8.
Insert
new
pretzel clip through hole in end of clevis pin.
NOTE
See
. Snap the loop of the pretzel clip over the
end of the clevis pin.
9.
Press the stop onto the motorcycle frame.
NOTE
When retracted, the leg should be seated against the stop.
10. Extend and retract jiffy stand leg several times to check
operation.
Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
death or serious injury. (00007a)
11. Rest motorcycle on jiffy stand.
2
1
sm06604a
1. Anchor pin
2. Leg spring mounting hole
Figure 2-221. Jiffy Stand (typical)
sm06605
Figure 2-222. Pretzel Clip
2013 Sportster Service: Chassis 2-157
2.39
SEAT
SEAT: XL MODELS
TORQUE VALUE
FASTENER
2.3-4.5 Nm
20-40
in-lbs
Seat mounting screw: XL
Models
Removal
1.
Remove screw to detach seat from rear fender.
2.
Slide seat forward.
3.
See
. Lift up slightly to detach keyhole bracket
from seat post.
NOTES
•
Solo Seat: See
.
•
Two-Up Seat: See
.
4.
Slide seat rearward to detach seat tongue (1) from rear
fuel tank bracket.
5.
Verify that tongue and mounting bracket (3) are tightly
secured to the seat bottom.
NOTE
The passenger strap is not sold separately. Replace entire
seat if the strap is damaged.
6.
If two-up seat, inspect passenger strap (4) for damage or
excessive wear.
om01376
Figure 2-223. Seat Post: XL Models
3
1
2
sm07135
1. Tongue
2. Keyhole
3. Mounting bracket
Figure 2-224. Seat: XL Solo
1
4
2
3
om01561a
1. Tongue
2. Keyhole
3. Mounting bracket
4. Passenger strap
Figure 2-225. Seat: XL Two-Up
Installation
1.
Position seat on frame with mounting bracket at rear.
2.
Slide seat forward until the tongue fits snugly under rear
fuel tank bracket.
3.
Push seat forward to engage keyhole onto seat post. Pull
seat back slightly.
NOTE
Mounting bracket of solo seat uses forward hole in rear fender.
Dual seat bracket uses rearward hole.
4.
See
. Install seat mounting screw with captive
washer to fasten seat mounting bracket to top of rear
fender.
5.
Pull up on seat to verify that it is locked in place.
2-158 2013 Sportster Service: Chassis
6.
Tighten seat mounting screw to 20-40
in-lbs
(2.3-4.5 Nm).
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)
7.
Pull up on seat again to verify that it is secured at all three
points.
5
2
6
4
7
1
3
sm07128a
1. Mounting bracket, snap-in
2. Mounting bracket, bolt-on
3. Seat mounting screw w/captive washer
4. Seat nut
5. Screw
6. Lockwasher
Figure 2-226. Seat Assembly: XL Models
SEAT: XR 1200X
Removal
1.
See
. Reach under front end of tailsection.
Press the two seat tabs inward.
2.
Pull front of seat upward to disengage seat from the front
end of the tailsection.
3.
Pull seat forward over fuel tank.
NOTES
•
When removing the seat, verify that the mounting bracket
under the seat is tightly secured to the seat bottom.
•
Check for loose or missing rivets.
•
Inspect passenger strap for damage or excessive wear.
The passenger strap is not sold separately. Replace entire
seat if the strap is damaged.
om01260
Figure 2-227. Front Seat Tabs (under tailsection): XR 1200X
Installation
1.
See
. Align the guides in the seat bracket with
the seat posts. Place rear of seat into tailsection.
2.
Push down on front of seat until the two tabs engage the
front end of tailsection.
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)
2013 Sportster Service: Chassis 2-159
2
1
4
5
3
6
om01259
1. Seat
2. Seat tabs
3. Seat posts
4. Passenger pillion
5. Pillion tabs
6. Pillion seat post
Figure 2-228. Seat and Pillion: XR 1200X
PASSENGER PILLION: XR 1200X
Removal
1.
See
. Lift the rear of pillion to disengage
grommet from the seat post.
2.
Pull pillion out from tailsection.
Installation
1.
See
. Insert pillion into trunk, aligning tabs on
pillion with the slots in the trunk.
2.
Push down firmly on rear of pillion until grommet fully
engages the seat post.
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)
2
3
1
om01277
1. Pillion
2. Tabs
3. Seat post
Figure 2-229. Passenger Pillion: XR 1200X
2-160 2013 Sportster Service: Chassis
2.40
RIDER FOOT CONTROLS: XL MID-MOUNT
CONTROLS
RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY
TORQUE VALUE
FASTENER
61-68 Nm
45-50 ft-lbs
Footrest mount fastener
17.6-23.0 Nm
13-17 ft-lbs
Brake pedal clevis screw
8.1- 12.2 Nm
72-108
in-lbs
Footrest wear peg
13.6-20.4 Nm
120-180
in-lbs
Brake rod to bell crank screw
13.6-20.4 Nm
120-180
in-lbs
Brake rod to brake pedal
screw
Removal
1.
Remove front muffler. See
.
2.
See
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
3.
Remove brake rod (5) from brake pedal (6) and master
cylinder bell crank.
4.
Remove retaining ring (7), screw (8) and clevis (9). Discard
retaining ring.
5.
Remove two fasteners (10) and right rider footrest/brake
pedal support bracket (11) from frame.
Installation
1.
Mount support bracket with two fasteners. Tighten to 45-
50 ft-lbs (61-68 Nm).
2.
Install brake pedal.
a.
Slide brake pedal onto clevis.
b.
Fit clevis to the support bracket.
c.
Line up hole in clevis with hole in support bracket.
Secure with screw.
d.
Tighten to 13-17 ft-lbs (17.6-23.0 Nm).
e.
Install
new
retaining ring.
NOTE
Position spring washer inside clevis with the square edge
toward the inside.
3.
Install footrest.
a.
Install footrest and spring washer on clevis.
b.
Align holes and push clevis pin from top down through
hole in clevis.
c.
Install
new
retaining ring.
4.
If removed, install wear peg. Tighten to 72-108
in-lbs
(8.1-
12.2 Nm).
5.
Install the brake rod.
a.
Apply
two
drops
of
LOCTITE
243
MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue)
to threads of both brake rod ball stud screws.
b.
Thread one end of brake rod into master cylinder bell
crank. Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
c.
Thread other end of brake rod into brake pedal.
Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
6.
Install front muffler. See
1
4
6
8
3
2
5
9
10
11
7
12
sm07568b
1. Retaining ring
2. Clevis pin
3. Footrest
4. Spring washer
5. Brake rod
6. Brake pedal
7. Retaining ring
8. Screw
9. Clevis
10. Screw (2)
11. Bracket
12. Wear peg
Figure 2-230. Right Footrest and Rear Brake Pedal
2013 Sportster Service: Chassis 2-161
LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY
TORQUE VALUE
FASTENER
21.7-27.1 Nm
16-20 ft-lbs
Gear shift lever pinch screw
10.9-16.3 Nm
96-144
in-lbs
Shifter peg screw
61-68 Nm
45-50 ft-lbs
Rider footrest support bracket
mounting screw
8.1- 12.2 Nm
72-108
in-lbs
Footrest wear peg
Removal
1.
See
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
2.
Remove two screws (5) and left rider footrest support
bracket (6) from frame.
3.
Remove screw (7) and shifter peg (8).
4.
Remove pinch screw (9) and washer (10). Remove shift
lever (12) and rubber washer (11).
Installation
1.
Install rubber washer and shift lever on transmission shift
lever shaft. Secure with washer and pinch screw. Tighten
to 16-20 ft-lbs (21.7-27.1 Nm).
NOTE
A new shifter peg screw comes with a lock patch.
2.
Install the shifter peg.
a.
Clean screw threads of the shifter peg screw and
apply one or two drops of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue)
to threads.
b.
Install shifter peg and screw.
c.
Tighten screw to 96-144
in-lbs
(10.9-16.3 Nm).
3.
Attach rider footrest support bracket to frame with two
screws. Tighten to 45-50 ft-lbs (61-68 Nm).
NOTE
Position spring washer inside support bracket mounting boss
with the square edge toward the inside.
4.
Install footrest.
a.
Install footrest with spring washer on footrest support
bracket.
b.
Align holes and push clevis pin from top down through
hole in support bracket.
c.
Install
new
retaining ring.
5.
If removed, install wear peg. Tighten to 72-108
in-lbs
(8.1-
12.2 Nm).
4
7
8
5
1
12
6
2
3
11
10
9
13
sm07568d
1. Retaining ring
2. Clevis pin
3. Footrest
4. Spring washer
5. Fastener
6. Support bracket
7. Screw
8. Shifter peg
9. Pinch screw
10. Washer
11. Rubber washer
12. Shift lever
13. Wear peg
Figure 2-231. Left Footrest and Shift Lever
2-162 2013 Sportster Service: Chassis
2.41
RIDER FOOT CONTROLS: XL FORWARD
CONTROLS
RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY
TORQUE VALUE
FASTENER
61-68 Nm
45-50 ft-lbs
Footrest mount fastener
17.6-23.0 Nm
13-17 ft-lbs
Brake pedal clevis screw
8.1-12.2 Nm
72-108
in-lbs
Footrest wear peg
13.6-20.4 Nm
120-180
in-lbs
Brake rod to bell crank screw
13.6-20.4 Nm
120-180
in-lbs
Brake rod to brake pedal
screw
Removal
1.
See
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
2.
Remove brake rod (5) from brake pedal (6) and master
cylinder bell crank (7).
3.
Remove retaining ring (8), screw (9) and clevis (10). Slide
brake pedal off clevis. Discard retaining ring.
4.
Remove two screws (11), footrest/brake pedal support
bracket (12) and J-clip (13) from frame.
Installation
1.
See
. Position J-clip (13) against frame as
shown. Mount footrest/brake pedal support bracket (12)
and J-clip to frame with screws (11). Tighten to 45-50 ft-
lbs (61-68 Nm).
2.
Slide brake pedal (6) onto clevis (10). Mount clevis on
footrest/brake pedal support bracket. Line up hole in clevis
with hole in support bracket. Secure with screw (9). Tighten
to 13-17 ft-lbs (17.6-23.0 Nm). Install
new
retaining ring
(8) on end of clevis.
3.
Install footrest (3) on clevis with spring washer (4). Make
sure spring washer is positioned inside clevis with the
square edge toward the inside. Align holes and push clevis
pin (2) from top down through hole in clevis. Secure with
new
retaining ring (1).
4.
If removed, install wear peg. Tighten to 72-108
in-lbs
(8.1-
12.2 Nm).
5.
Apply two drops of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads of
both brake rod ball stud screws.
6.
Thread one end of brake rod (5) into master cylinder bell
crank (7). Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
7.
Thread other end of brake rod into brake pedal. Tighten
to 120-180
in-lbs
(13.6-20.4 Nm).
9
1
6
7
2
12
11
5
10
13
4
3
8
14
sm02207c
1. Retaining ring
2. Clevis pin
3. Footrest
4. Spring washer
5. Brake rod
6. Brake pedal
7. Bell crank
8. Retaining ring
9. Screw
10. Clevis
11. Screw (2)
12. Footrest/brake pedal support bracket
13. J-clip
14. Wear peg
Figure 2-232. Brake Side Forward Controls
2013 Sportster Service: Chassis 2-163
LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY
TORQUE VALUE
FASTENER
21.7-27.1 Nm
16-20 ft-lbs
Shift lever pinch screw
61-68 Nm
45-50 ft-lbs
Footrest mount fastener
17.6-23.0 Nm
13-17 ft-lbs
Shift pedal clevis screw
8.1-12.2 Nm
72-108
in-lbs
Footrest wear peg
13.6-20.4 Nm
120-180
in-lbs
Shifter rod to shift lever screw
13.6-20.4 Nm
120-180
in-lbs
Shifter rod to shift lever screw
10.9-16.3 Nm
96-144
in-lbs
Shifter peg screw
Removal
1.
See
. Remove retaining ring (1), clevis pin
(2), footrest (3) and spring washer (4). Discard retaining
ring.
2.
Remove screw (5) and shifter peg (6).
3.
Remove the shifter rod screws (7) and the shifter rod (8)
from shifter lever assembly (9) and shift lever (10).
4.
Remove retaining ring (11), screw (12) and clevis (13).
Slide shifter lever assembly off clevis. Discard retaining
ring.
5.
Remove two screws (14), footrest/shifter lever support
bracket (15) and j-clip (16) from frame.
6.
Remove pinch screw (17), washer (18), shift lever (10)
and rubber washer (19) from transmission shift shaft.
Installation
1.
See
. Install rubber washer (19) and shift
lever (10) onto transmission shifter shaft, with shift lever
arm pointing straight down. Secure with pinch screw (17)
and washer (18). Tighten pinch screw to 16-20 ft-lbs (21.7-
27.1 Nm).
2.
Mount j-clip (16) and footrest/shift lever support bracket
(15) to frame with two screws (14). Tighten to 45-50 ft-lbs
(61-68 Nm).
3.
Install shift lever clevis:
a.
Slide shifter lever assembly (9) onto clevis (13).
b.
Mount clevis on footrest/shifter lever support bracket.
c.
Line up hole in clevis with hole in support bracket.
d.
Secure with screw (12). Tighten to 13-17 ft-lbs (17.6-
23.0 Nm).
e.
Install retaining ring (11) on end of clevis.
4.
Mount footrest (3) on clevis with spring washer (4):
a.
Position the spring washer inside clevis with the
square edge toward the inside.
b.
Align holes.
c.
Push clevis pin (2) from top down through hole in
clevis.
d.
Secure with
new
retaining ring (1).
5.
If removed, install wear peg. Tighten to 72-108
in-lbs
(8.1-
12.2 Nm).
6.
Thread screw (7) in one end of shifter rod (8) into shift
lever (10). Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
7.
Thread screw (7) in other end of shifter rod into shift lever
assembly (9). Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
NOTE
A new shifter peg screw has lock patch.
8.
If re-using shifter peg screw, clean screw threads and
apply one or two drops of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
threads.
9.
Install shifter peg (6). Secure with screw (5). Tighten to
96-144
in-lbs
(10.9-16.3 Nm).
2-164 2013 Sportster Service: Chassis
2
8
14
1
16
5
6
18
9
3
4
17
12
11
10
15
19
13
7
20
sm02208c
1. Retaining ring
2. Clevis pin
3. Footrest
4. Spring washer
5. Screw
6. Shifter peg
7. Screw (2)
8. Shifter rod assembly
9. Shifter lever assembly
10. Shift lever
11. Retaining ring
12. Screw
13. Clevis
14. Screw (2)
15. Footrest/shifter lever support bracket
16. J-clip
17. Pinch screw
18. Washer
19. Rubber washer
20. Wear peg
Figure 2-233. Shifter Side Forward Controls
ADJUSTING SHIFT PEDAL: FORWARD
CONTROLS MODELS
TORQUE VALUE
FASTENER
13.6-20.4 Nm
120-180
in-lbs
Shift rod screw
9.5-14.9 Nm
84-132
in-lbs
Shift rod jamnuts
1.
See
. Loosen locknuts (1) on shift rod (2).
2.
Remove ball joint screw (3).
NOTE
Adjust so that an equal number of threads (4) are visible on
both ends of the shift rod.
3.
Turn ball joint or shift rod to adjust rod length.
4.
Temporarily attach ball joint to shift lever.
5.
Measure the shift lever angle (5). Remove and adjust as
necessary until the angle is 45 degrees.
6.
Tighten to 120-180
in-lbs
(13.6-20.4 Nm).
7.
Hold shifter rod. Tighten locknuts to 84-132
in-lbs
(9.5-
14.9 Nm).
5
1
2
4
3
4
1
sm07589
1. Locknut
2. Shift rod
3. Ball joint screw
4. Threads
5. 45 degrees
Figure 2-234. Shifter Linkage: Models with Forward
Controls
2013 Sportster Service: Chassis 2-165
2.42
RIDER FOOT CONTROLS: XR 1200X
RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY
TORQUE VALUE
FASTENER
17.6-23.0 Nm
13-17 ft-lbs
Footrest clevis fastener: XR
1200X
8.1-12.2 Nm
72-108
in-lbs
Footrest wear peg
Removal
1.
Remove clevis pin connecting master cylinder to brake
pedal. See
2.12 REAR BRAKE MASTER CYLINDER: XR
2.
If necessary, remove wear peg (11).
3.
See
. Remove retaining ring (10) and washer
(9). Discard retaining ring.
4.
Remove clevis pin (5), spring (7), and footrest (8).
5.
Remove bolt (3), footrest clevis (6), and brake pedal (4).
6.
If necessary, remove bracket (1). The master cylinder
must be disconnected from the bracket or brake line dis-
connected prior to removing the two fasteners (2). See
2.12 REAR BRAKE MASTER CYLINDER: XR 1200X
.
Installation
1.
If removed, install master cylinder/footrest bracket. See
2.12 REAR BRAKE MASTER CYLINDER: XR 1200X
.
2.
See
. Install brake pedal on footrest clevis
and install footrest clevis. Tighten bolt (3) to 13-17 ft-lbs
(17.6-23.0 Nm).
3.
Install footrest (8) and spring (7) on clevis and secure with
clevis pin (5). Install washer (9) and
new
retaining ring
(10).
4.
If removed, install wear peg and tighten to 72-108
in-lbs
(8.1-12.2 Nm).
5.
Connect brake pedal to master cylinder. See
BRAKE MASTER CYLINDER: XR 1200X
.
10
11
9
8
7
6
1
4
2
2
5
3
sm05342
1. Master cylinder/footrest bracket
2. Fastener
3. Footrest clevis bolt
4. Brake pedal
5. Clevis pin
6. Footrest clevis
7. Spring
8. Footrest
9. Washer
10. Retaining ring
11. Wear peg
Figure 2-235. Rider Foot Control, Right Side: XR 1200X
2-166 2013 Sportster Service: Chassis
LEFT FOOTREST AND SHIFT LEVER
ASSEMBLY
TORQUE VALUE
FASTENER
61-68 Nm
45-50 ft-lbs
Footrest bracket fastener: XR
1200X
17.6-23.0 Nm
13-17 ft-lbs
Footrest clevis fastener: XR
1200X
10.9-16.3 Nm
96-144
in-lbs
Shifter peg screw
8.1-12.2 Nm
72-108
in-lbs
Footrest wear peg
13.6-20.3 Nm
120-180
in-lbs
Shift linkage fastener
Removal
1.
See
. Remove fasteners (11) and remove
linkage (12).
2.
If necessary, remove wear peg (9).
3.
Remove retaining ring (4) and washer (5). Discard
retaining ring.
4.
Remove clevis pin (10), spring (7), and footrest (8).
5.
Remove bolt (3), footrest clevis (6), and foot shift lever
(15).
6.
Remove shifter peg (13).
7.
If necessary, remove fasteners (2) and bracket (1).
Installation
1.
See
. If removed, install bracket (1). Tighten
fasteners (2) to 45-50 ft-lbs (61-68 Nm).
2.
Install foot shift lever on footrest clevis. Install footrest
clevis and bolt (3). Tighten to 13-17 ft-lbs (17.6-23.0 Nm).
3.
Install footrest (8) and spring (7) on clevis. Secure with
clevis pin (10). Install washer (5) and
new
retaining ring
(4).
4.
Install shifter peg (13). Tighten to 96-144
in-lbs
(10.9-16.3
Nm).
5.
If removed, install wear peg. Tighten to 72-108
in-lbs
(8.1-
12.2 Nm).
6.
Connect linkage (12) between foot shift lever (15) and
transmission shift lever (14) using fasteners (11). Tighten
to 120-180
in-lbs
(13.6-20.3 Nm).
7.
Check shift linkage adjustment. Adjust as necessary.
1
2
4
5
6
8
7
9
10
11
12
11
13
14
16
15
3
sm05348
1. Bracket
2. Fastener (2)
3. Footrest clevis bolt
4. Retaining ring
5. Washer
6. Footrest clevis
7. Spring
8. Footrest
9. Wear peg
10. Clevis pin
11. Fastener (2)
12. Shift linkage
13. Shifter peg
14. Transmission shift lever
15. Foot shift lever
16. Bushing
Figure 2-236. Rider Foot Control, Left Side: XR 1200X
2013 Sportster Service: Chassis 2-167
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