Harley Davidson 2013 Sportster Models. Service Manual — page 39
3.19
CRANKCASE
GENERAL
When replacing the connecting rod and flywheel assembly,
the pinion shaft bearing, or the sprocket shaft bearing, inspect
and make repairs to the cylinder heads, the cylinders, the gear
case and the transmission. Perform a complete engine over-
haul.
NOTE
When engine is removed from chassis, do not lay engine on
primary side. Laying engine on primary side will damage the
clutch cable end fitting. If fitting is damaged, clutch cable must
be replaced.
DISASSEMBLY
TOOL NAME
PART NUMBER
CRANKCASE BEARING
REMOVER/INSTALLER WITH
ADAPTER
B-45655, HD-42720-
2, HD-46663
SNAP-ON BODY DENT PULLER
CJ 114
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586-A
1.
Disassemble crankcase, see
.
NOTE
Remove either the pinion shaft bearing or the left main bearing
with this procedure.
2.
See
. Pinion shaft bearing assembly (3) will
remain on pinion shaft (2) when flywheel assembly (1) is
removed from right crankcase. Using TRANSMISSION
SHAFT RETAINING RING PLIERS (Part No. J-5586-A),
remove retaining ring (4) and slip bearing off pinion shaft.
1
2
3
4
sm06555
1. Flywheel assembly
2. Pinion shaft
3. Pinion shaft bearing assembly
4. Retaining ring
Figure 3-121. Removing Pinion Shaft Bearing Retaining
Ring
NOTE
The sprocket shaft inner race is not replaceable. Replace
crankshaft if race is worn or damaged.
3.
See
. Remove outer left main bearing
retaining ring.
4.
Remove left main oil seal from left crankcase using SNAP-
ON BODY DENT PULLER (Part No. CJ 114).
5.
Remove thrust washer next to left main bearing.
2013 Sportster Service: Engine 3-93
sm01491a
Figure 3-122. Removing Left Main Oil Seal Retaining Ring
6.
See
. Remove left main bearing retaining ring
from the inside of the left crankcase.
NOTE
Press the left main bearing from the outside of the left crank-
case toward the inside. A shoulder in the left crankcase pre-
vents the bearing from being pressed towards the outside.
7.
See
. Using CRANKCASE BEARING
REMOVER/INSTALLER WITH ADAPTER (Part No. B-
45655, HD-42720-2, HD-46663), press left main bearing
out of the left crankcase.
a.
Place support tube (1) on press bed with recessed
cup end facing up.
b.
With the outboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.
c.
Place adapter (4) over left main bearing. Insert
pilot/driver (5) through adapter, through left main
bearing and into support tube.
d.
Carefully apply pressure with press ram (6) until left
main bearing drops free.
sm01503a
Figure 3-123. Removing Left Main Bearing Retaining Ring
4
6
3
2
5
1
sm01494a
1. Support tube
2. Left crankcase
3. Crankshaft bearing bore
4. Adapter
5. Pilot/driver
6. Press ram
Figure 3-124. Removing Left Main Bearing from Crankcase
3-94 2013 Sportster Service: Engine
FITTING PINION BEARINGS
TOOL NAME
PART NUMBER
END CAP
HD-34902-7
FORCING SCREW
J-21686-12
BRIDGE
J-7830-5
BEARING SEPARATOR
SNAP-ON TOOLS
STOCK NO. CJ950
Outer and Inner Races
The outer race is a pressed-in bushing in the right crankcase.
The inner race is pressed on the pinion shaft.
See
. To remove pinion shaft inner race, use
BEARING SEPARATOR (Part No. Snap-on Tools Stock No.
CJ950), three items from END CAP (Part No. HD-34902-7),
BRIDGE (Part No. J-7830-5) and FORCING SCREW (Part
No. J-21686-12), and two bolts. Apply heat to race to aid
removal.
1
2
3
5
6
4
sm01495b
1. Forcing screw
2. Bridge
3. End cap
4. Bolts (2)
5. Bearing separator
6. Flywheel support fixture
Figure 3-125. Pulling Pinion Shaft Inner Bearing
Pinion bearing selection is based on the largest measured
outside diameter (OD) of the inner race and the smallest
measured inside diameter (ID) of the outer race (crankcase
bushing).
A running clearance of 0.0002-0.0008 in (0.005-0.020 mm) is
established during crankcase set or flywheel assembly
replacement and engine rebuild.
See
. Installed inner races are identified at the
factory as shown.
See
. Outer races are identified at the factory as
shown.
NOTE
The different sizes of crankcase sets and flywheel assemblies
do not have separate part numbers. Replacement crankcase
sets can have a class 1, 2 or 3 pinion outer race. Replacement
flywheel assemblies can have either a class A or B inner race.
2
1
sm01497a
1. Paint dot
2. Inner race
Figure 3-126. Factory Inner Race Sizes
Table 3-35. Inner Race Specifications
IDENTIFICATION*
CLASS
RACE OD
mm
in
White
A
31.745-31.750
1.2498-1.2500
Green
B
31.740-31.745
1.2496-1.2498
* Paint dot on end of spline.
Bearing Selection
See
. Pinion bearing roller OD cannot be measured
to required accuracy with a micrometer. Select bearings using
the identification information given for inner and outer races
and bearings. Refer to
.
NOTE
If either inner or outer race show wear, measure both races to
confirm correct bearing fit of 0.0002-0.0008 in (0.005-0.020
mm). The service wear limit of the outer race ID is 1.5656 in
(39.776 mm).
sm03413
Figure 3-127. Bearing Roller OD (A)
2013 Sportster Service: Engine 3-95
Table 3-36. Roller Specifications
IDENTIFICATION
(PACKAGE COLOR)
ROLLER OD (A)
Red
Largest
Blue
White (gray)
Green
Smallest
Table 3-37. Outer Race Specifications
STAMPED
IDENTIFICATION*
CLASS
NO.
RACE ID
mm
in
1
1
39.741-39-746
1.5646-1.5648
2
2
39.746-39.751
1.5648-1.5650
3
3
39.751-39.756
1.5650-1.5652
* Stamped number inside crankcase near race.
1
2
3
sm03412
1. Outer race
2. Stamped class no.
3. Right crankcase
Figure 3-128. Factory Outer Race Sizes
Table 3-38. Pinion Shaft Bearing Selection
BEARING SIZE AS IDENTIFIED BY COLOR CODING
OUTER RACE ID
FACTORY
STAMPED
NUMBER
mm
in
Red
39.761-39.766
1.5654-1.5656
Blue
Red
39.756-39.761
1.5652-1.5654
White-gray
Blue
Red
39.751-39.756
1.5650-1.5652
3
Green
White-gray
Blue
39.746-39.751
1.5648-1.5650
2
Green
White-gray
39.741-39.746
1.5646-1.5648
1
1.2500-1.2502
1.2498-1.2500
1.2496-1.2498
Inner Race OD (in)
31.750-31.755
31.745-31.750
31.740-31.745
Inner Race OD (mm)
White
Green
Factory Color Code
NOTE
Removal and installation of the inner and outer bearing races
require the use of shop-made tools. See
,
, and
.
1.
Measure ID of outer race at four places with a dial bore
gauge. Take measurement on ID where bearing rollers
ride. Record the four measurements.
Table 3-39. Used Pinion Bearing Outer Race Specifications
mm
in
ITEM
39.776
1.5656
Largest ID allowed
0.005
0.0002
Roundness of ID (within)
0.005
0.0002
Taper (within )
2.
If the largest measurement is larger than 1.5656 in (39.776
mm) or the required lapping to remove wear marks would
enlarge bore beyond 1.5656 in (39.776 mm), continue at
Step 8. Refer to
3.
If the largest measurement is 1.5656 in (39.776 mm) or
less, cover the cam bearings with masking tape to prevent
debris from entering bearings. Assemble crankcase halves.
NOTE
The next step requires lapping the outer race. To keep sprocket
shaft and pinion shaft bearings aligned, support the lap by an
adaptor or pilot in the left crankcase.
4.
Lap the outer race. The race must be lapped until all wear
marks are removed. See
.
5.
After lapping race, again measure ID of race at four places
and record the measurements.
6.
Check measurements against the specifications listed in
7.
If lapping increased bore ID to larger than 1.5656 in
(39.776 mm), go to next step. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.
3-96 2013 Sportster Service: Engine
NOTE
Always use the smallest outer race ID measurement and the
largest OD inner race measurement when selecting bearings.
8.
Press the outer race from the right crankcase. Press
new
outer race into crankcase flush with inside edge of cast-in
insert.
9.
The
new
outer race must be lapped slightly to true and
align with left case bearing to specifications. Refer to
. See
3.19 CRANKCASE, Lapping Engine Main
.
Table 3-40. New Pinion Bearing Outer Race Fit and Finish
SPECIFICATION
ITEM
mm
in
39.741-39.756
1.5646-1.5652
ID
0.005
0.0002
Roundness within:
0.005
0.0002
Taper within:
16 RMS
Surface finish
10. See
. Pull inner race from pinion shaft using
BEARING SEPARATOR (Part No. Snap-on Tools Stock
No. CJ950), three items from END CAP (Part No. HD-
34902-7), BRIDGE (Part No. J-7830-5) and FORCING
SCREW (Part No. J-21686-12), and two bolts. Apply heat
to race to aid removal.
11. See
. Press
new
inner race on pinion shaft
using shop-made tool. When the tool bottoms against the
flywheel, the correct inner race location is automatically
established. The
new
inner race must be machined to
dimension based on the finished lapped ID of the outer
race. Refer to
Table 3-41. Inner Race Fit and Finish
SPECIFICATION
ITEM
mm
in
0.005
0.0002
Roundness within:
0.005
0.0002
Taper within:
16 RMS
Surface finish
2
1
3
sm03414
1. Pinion shaft inner race
2. Flywheel (gear side)
3. 1.135-1.145 in (28.83-29.08 mm)
Figure 3-129. Inner Race Location
Inner Bearing Finish Example
The following example illustrates how to determine the required
inner race OD:
1.
If smallest measured ID of outer race is 1.5651 in (39.754
mm), an inner race OD range of 1.2496-1.2504 in (31.740-
31.760 mm) is required. Refer to
NOTE
Have machinist precision grind outer race to center or middle
of required OD range. This will prevent grinding outer race
undersize and gives a more easily achieved tolerance range.
2.
Precision grind inner race OD to the middle of the desired
range. Refer to
3.
Measure OD at four places. Verify that OD is to specifica-
tion. Refer to
4.
For example purposes:
a.
The largest measured OD of inner race after grinding
is 1.2499 in (31.747 mm) OD.
b.
With a 1.5651 in (39.754 mm) ID outer race and a
1.2499 in (31.747 mm) OD inner race, a blue bearing
is required. Refer to
2013 Sportster Service: Engine 3-97
4
5
3
2
1
sm03435
1. 2.00 in (50.8 mm)
2. 1.00 in (25.4 mm)
3. 1.560 in (39.62 mm)
4. 0.187 in (4.75 mm)
5. 5/16 drill
Figure 3-130. Pinion Shaft Outer Race Installation Tool
4
5
1
3
2
sm03436
1. 1.70 in (43.2 mm)
2. 1.00 in (25.4 mm)
3. 1.560 in (39.62 mm)
4. 0.187 in (4.75 mm)
5. 5/16 drill
Figure 3-131. Pinion Shaft Outer Race Removal Tool
3
4
5
2
1
sm03437
1. 1.50 in (38.1 mm)
2. 1.00 in (25.4 mm)
3. 5.50 in (139.7 mm)
4. 1.135-1.145 in (28.83-29.08 mm)
5. 1.262-1.272 in (32.05-32.31 mm)
Figure 3-132. Pinion Shaft Inner Race Installation Tool
LAPPING ENGINE MAIN BEARING RACES
TOOL NAME
PART NUMBER
LAPPING TOOL ADAPTER
HD-46287
CRANKCASE MAIN BEARING LAP-
PING TOOL
HD-96710-40C
CRANKCASE MAIN BEARING LAP
HD-96718-87
1.
See
. Obtain CRANKCASE MAIN BEARING
LAPPING TOOL (Part No. HD-96710-40C). Assemble
CRANKCASE MAIN BEARING LAP (Part No. HD-96718-
87) to lapping handle.
NOTE
Left main bearing must be installed in left crankcase to use
LAPPING TOOL ADAPTER (Part No. HD-46287) in the next
step. See
3.22 BOTTOM END OVERHAUL: ASSEMBLY,
.
2.
Assemble LAPPING TOOL ADAPTER (Part No. HD-
46287) to left main bearing.
3.
Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right).
4.
Insert lap shaft with arbor assembled through pinion
bearing bushing and into lapping tool adapter. Tighten
arbor expansion collars using a length of 0.156 in (3.96
mm) rod as spanner until arbor begins to drag. Do not
adjust arbor snug in bushing or bushing will bell. Belling
3-98 2013 Sportster Service: Engine
is a condition where hole is larger at ends than it is in the
center.
5.
Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposition
lap in bushing and turn handle at moderate hand speed.
Work lap back and forth in bushing, as it is revolved, to
avoid grooving and tapering.
6.
At frequent intervals, remove lap from crankcase, wash
and inspect bushing. Lapping is completed when entire
bushing surface has a dull, satin finish rather than a glossy,
smooth appearance.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
7.
When finished, flush off lap tool using cleaning solvent
and dry using compressed air. Apply fresh, light coat of
fine lapping compound.
sm01499
Figure 3-133. Lapping Pinion Shaft Main Bearing
2013 Sportster Service: Engine 3-99
3.20
OIL PUMP: XL MODELS
GENERAL
The oil pump seldom needs servicing. Check for all possible
malfunctions related to oil pressure before disassembling oil
pump.
1.
Make sure all oil line connections are tight. Verify that lines
are not pinched or damaged.
2.
Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.
3.
Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.
See
,
and
15
14
13
11
10
9
5
1
3
2
4
7
12
8
6
sm03410
9.
1.
Retaining ring
Oil pump cover
2.
10.
Screw w/ washer (2)
Thrust washer
11.
3.
O-ring
Torx screw (2)
4.
12.
Connector
Oil pump body
13.
5.
Elbow fitting
Hose fitting
6.
14.
Feed gerotor set
Gear shaft
15.
7.
Gasket
Gerotor separator plate
8. Scavenge gerotor set
Figure 3-134. Oil Pump: XL Models
3-100 2013 Sportster Service: Engine
REMOVAL
NOTE
The oil pump can be removed with engine in frame and without
removing gearcase cover.
1.
Drain oil from oil tank.
NOTE
See
. Do not remove oil pump feed fitting (2) from
the pump (1). Hold oil pump feed fitting and loosen large high
pressure hose fitting nut (3). Then remove high pressure hose
(4) from oil pump feed fitting.
2.
See
. Remove high pressure feed hose (4)
from oil pump (1).
3
1
4
2
sm01486a
1. Oil pump
2. Oil pump feed fitting
3. High pressure hose fitting nut
4. High pressure feed hose (to oil filter)
Figure 3-135. Oil Pump Feed Hose
NOTE
See
. The oil pump is designed to be removed as
a complete assembly by removing the two long screws (2) at
opposite corners of the pump. The other two screws (3) hold
the pump together so that it may be removed and installed as
a unit.
3.
See
. Carefully remove two screws (2) that
secure oil pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket (15).
4.
Disconnect and tag the two remaining oil hoses from the
pump.
DISASSEMBLY
1.
See
. Remove two Torx screws (3). Lift cover
(1) off body (12). Remove and discard O-ring (11).
2.
Slide both pieces of feed gerotor set (6), separator plate
(7) and both pieces of scavenge gerotor set (8) off gear
shaft (14).
3.
Remove and discard retaining ring (9). Remove thrust
washer (10) and gear shaft.
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2.
See
. Inspect both gerotor sets for wear.
a.
Mesh pieces of each set together as shown.
b.
Use a feeler gauge to determine clearance.
c.
The SERVICE WEAR LIMIT between gerotors is
0.004 in (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.
d.
Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.
1
2
3
sm03409
1. Outer gerotor
2. Inner gerotor
3. Wear limit
Figure 3-136. Gerotor Wear Limits
ASSEMBLY
TORQUE VALUE
FASTENER
7.9-9.0 Nm
70-80
in-lbs
Oil pump cover screws
NOTE
Liberally coat all moving parts with clean engine oil to lubricate
at start-up.
1.
See
. Install gear shaft (14) through oil pump
body (12). Position thrust washer (10) over end of shaft.
Install
new
retaining ring (9) into groove in shaft.
2.
Insert inner gerotor of the scavenge gerotor set (8) over
gear shaft.
3.
Place outer gerotor over inner to complete scavenge set.
4.
Position separator plate (7) into case and line up slots on
perimeter with tabs inside oil pump body.
5.
Place feed gerotor set (6) over gear shaft.
6.
Install a
new
O-ring (11) into groove in oil pump cover (1).
Place cover onto pump body. Install two Torx cover screws
(3). Tighten to 70-80
in-lbs
(7.9-9.0 Nm).
2013 Sportster Service: Engine 3-101
INSTALLATION
TORQUE VALUE
FASTENER
14.1-16.9 Nm
125-150
in-lbs
Oil pump to crankcase screw
11.3-13.6 Nm
100-120
in-lbs
Oil pump feed fitting
6.8-10.2 Nm
60-90
in-lbs
Oil pump high pressure feed
hose to crankcase fitting
9.6-11.8 Nm
85-105
in-lbs
Oil pump high pressure feed
hose fitting nut
1.
See
. Place
new
mounting gasket (15) in
position.
2.
Secure pump to crankcase with two screws (2). Tighten
to 125-150
in-lbs
(14.1-16.9 Nm).
NOTE
Use new hose clamps to secure oil tank feed hose and vent
hose to oil pump fittings. If fittings were removed, use TEFLON
PIPE SEALANT or HYLOMAR on fitting threads.
3.
Install hoses on oil pump. Attach oil tank feed hose to hose
fitting (5) with
new
clamp. Attach oil tank vent hose to
elbow fitting (13) with
new
clamp.
4.
See
. If oil pump feed fitting (2) was removed
for any reason, install fitting in oil pump (1) cover. Tighten
to 100-120
in-lbs
(11.3-13.6 Nm).
5.
If high pressure feed hose (4), was removed completely,
install end opposite high pressure fitting nut (3) in crank-
case. Tighten to 60-90
in-lbs
(6.8-10.2 Nm).
6.
Install high pressure feed hose fitting nut (3) onto feed fit-
ting on front of oil pump. Hold oil pump feed fitting with a
wrench and tighten high pressure hose fitting nut to 85-
105
in-lbs
(9.6-11.8 Nm).
7.
Fill oil tank with proper oil. See
.
3-102 2013 Sportster Service: Engine
3.21
OIL PUMP: XR 1200X
GENERAL
The oil pump seldom needs servicing. Check for all possible
malfunctions related to oil pressure before disassembling oil
pump.
1.
Make sure all oil line connections are tight. Verify that lines
are not pinched or damaged.
2.
Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.
3.
Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.
See
,
and
2013 Sportster Service: Engine 3-103
1
2
3
7
8
4
5
6
10
9
13
14
15
12
16
17
18
19
11
21
22
27
26
25
24
23
28
20
sm05382
21.
11.
1.
Line connector fitting, oil to
cooler
Oil pump/gearcase housing
Oil pump rotor cover
2.
12.
O-rings, rotor cover
O-ring
22.
13.
3.
Thermostat (oil from cooler)
Check valve housing, cylinder
head oil
Retainer
4.
23.
O-ring, internal (1 each fitting)
Plugs
14.
24.
O-ring
5.
Bypass valve shuttle
Line connector fitting, return
oil
25.
15.
Spring, bypass valve
Fastener (2)
6.
16.
O-ring, external (1 each fitting)
26.
Plug
O-ring
27.
17.
7.
Plug
O-ring
Scavenge gerotor set
8.
28.
18.
Feed gerotor set
Fastener (6)
Spring
19.
9.
Check ball
Line connector fitting, supply
oil
20. Gasket
10. Vent line fitting
Figure 3-137. Oil Pump: XR 1200X
DISASSEMBLY
NOTE
The oil pump can be removed with engine in frame and without
removing gearcase cover.
1.
Remove the exhaust system. See
2.
Drain oil from oil tank.
3.
Place pan under oil pump to collect oil.
4.
See
. Remove nine fasteners (1) and remove
gearcase and oil pump cover (2).
5.
See
. Remove oil cooler rigid lines (3) from
gearcase cover. See
SYSTEM: XR 1200X, Oil Pump Lines
.
6.
Remove six screws (1) and remove oil pump cover (2).
Discard cover O-rings.
3-104 2013 Sportster Service: Engine
NOTE
If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they are removed.
Failure to do so can result in accelerated wear and possible
engine failure.
7.
See
. Wipe the oil film from the exposed sur-
faces of the rotors (1, 2) and mark each rotor using a
permanent marker to aid in reassembly.
NOTE
The surface tension of the remaining oil film will make the rotors
"stick" against the bottom of the bore. Never use a metallic tool
to remove oil pump rotors. This could result in damage requiring
rotor or gearcase cover replacement.
8.
Grasp the outer rotor (1) of each stage and pull from
housing bore.
9.
Remove each inner rotor (2).
10. Remove the thermostat fitting (3) and spring.
11. Remove the plug and bypass valve components (4).
12. If necessary, remove remaining line connector fittings from
gearcase cover.
13. Remove and discard all used O-rings.
1
2
sm05003a
1. Fastener (9)
2. Cover
Figure 3-138. Oil Pump Cover: XR 1200X
2
1
3
3
sm05018b
1. Cover screw (6)
2. Rotor cover
3. Oil cooler rigid lines
Figure 3-139. Oil Pump Rotor Cover: XR 1200X
1
2
4
3
sm05019
1. Outer rotor
2. Inner rotor
3. Thermostat
4. Bypass valve plug
Figure 3-140. Oil Pump: XR 1200X
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2013 Sportster Service: Engine 3-105
2.
See
. Inspect both gerotor sets for wear.
a.
Mesh pieces of each set together as shown.
b.
Use a feeler gauge to determine clearance.
c.
The SERVICE WEAR LIMIT between gerotors is
0.004 in (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.
d.
Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.
3.
See
. Inspect thermostat spring for distortion
or cracks. Inspect rubber seal for damage. Replace ther-
mostat assembly as necessary.
1
2
3
sm03409
1. Outer gerotor
2. Inner gerotor
3. Wear limit
Figure 3-141. Gerotor Wear Limits
sm05659
Figure 3-142. Thermostat: XR 1200X
ASSEMBLY
TORQUE VALUE
FASTENER
12.2-17.6 Nm
108-156
in-lbs
Gearcase housing plug
10.2-13.6 Nm
90-120
in-lbs
Oil pump rotor cover screw:
XR 1200X
10.2-13.6 Nm
90-120
in-lbs
Gearcase cover fastener
NOTE
Used O-rings can leak. Always install new O-rings when per-
forming repairs.
1.
Install
new
internal O-rings in each line connector fitting.
2.
Install
new
external O-rings on all connector fittings that
have been removed.
NOTE
Apply a light coat of new engine oil to the shuttle valve compon-
ents and oil pump rotors during assembly.
3.
See
. Install bypass valve components (4).
Tighten plug to 108-156
in-lbs
(12.2-17.6 Nm).
4.
Install thermostat and oil cooler line fitting (3).
NOTE
If oil pump rotors are to be re-used, they must be installed in
the original location and orientation. Make sure the mark made
during disassembly is visible when installing the rotors. Failure
to do so can result in accelerated wear and possible engine
failure.
5.
Install each outer rotor (1) in its original location.
6.
Install each inner rotor (2) in its original location.
7.
See
. Install
new
O-rings in oil pump rotor
cover and install cover using six fasteners (1). Tighten
fasteners to 90-120
in-lbs
(10.2-13.6 Nm).
8.
Install oil cooler rigid lines (3) to quick connect fittings. See
3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil
Pump Lines
.
9.
See
. Install oil pump/cam support housing
cover. Secure with 9 socket fasteners. Tighten in the
sequence shown to 90-120
in-lbs
(10.2-13.6 Nm).
10. Install the exhaust system. See
.
3-106 2013 Sportster Service: Engine
3
1
2
sm00294
1. Removal end of bearing tool
2. Installation end of bearing tool
3. Bearing guide, installer
Figure 5-26. Clutch Shell Bearing Remover/Installer
sm00295a
Figure 5-27. Removing Clutch Shell Needle Bearing
2
1
sm00296
1. Place needle bearing on tool in this location
2. Bearing guide
Figure 5-28. Bearing Installer
1
2
sm00297a
1. Needle bearing
2. Clutch shell
Figure 5-29. Installing Clutch Shell Needle Bearing
ASSEMBLY
TOOL NAME
PART NUMBER
SPRING COMPRESSING TOOL
HD-38515-A
1.
Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.
2.
See
. Install narrow friction plate on the clutch
hub, engaging tabs on plate with slots in clutch shell.
3.
See
. Install damper spring seat (1) on clutch
hub so that it seats inboard of narrow friction plate (3).
5-20 2013 Sportster Service: Drive/Transmission
4.
Install damper spring (2) on clutch hub with the concave
side up (facing opposite damper spring seat).
5.
Install a steel plate (4) and then a friction plate (5) on the
clutch hub. Install six remaining sets in the same manner,
alternating between steel plates and friction plates.
1
2
sm00285a
1. Narrow plate
2. Regular plate
Figure 5-30. Friction Plates
6.
Place pressure plate, diaphragm spring, adjusting screw
assembly with
new
retaining ring and spring seat onto
clutch pack.
7.
Install the retaining ring:
a.
See
. Align square openings of pressure
plate and diaphragm spring so that the assembly can
be installed over prongs on clutch hub.
b.
Position spring seat with its larger outer diameter side
toward diaphragm spring.
NOTE
Turn compressing tool handle only the amount required
to install spring seat and retaining ring. Excessive com-
pression of diaphragm spring could damage clutch pres-
sure plate.
c.
Install SPRING COMPRESSING TOOL (Part No. HD-
38515-A) onto clutch hub against diaphragm spring.
d.
Place a wrench on the clutch spring forcing screw
flats to prevent the forcing screw from turning.
e.
Turn compressing tool handle clockwise until dia-
phragm spring compresses just enough to install new
retaining ring into the groove in clutch hub prongs.
f.
With retaining ring fully seated in groove of clutch
hub, remove the compression tool.
NOTE
Remove the tool to allow the diaphragm spring to move outward
forcing the spring seat up into the inside of the retaining ring.
The spring seat is an operating surface for the diaphragm
spring and prevents the retaining ring from coming out.
5
1
2
4
3
sm00286a
1. Damper spring seat
2. Damper spring
3. Narrow friction plate
4. Steel plate
5. Friction plate
Figure 5-31. Clutch Pack Stack-Up
1
3
5
4
2
sm01265a
1. Diaphragm spring (pressure plate below)
2. Prongs on clutch hub
3. Retaining ring
4. Adjusting screw assembly
5. Spring seat
Figure 5-32. Spring Seat Installation
2013 Sportster Service: Drive/Transmission 5-21
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