Harley Davidson 2013 Sportster Models. Service Manual — page 35
ENGINE REMOVED FROM CHASSIS
Table 3-27. Engine Removed from Chassis: Flywheel Compartment Service or Complete Engine Overhaul
COMPONENT REPAIR
PROCEDURES
SERVICE PROCEDURE
Remove engine from chassis. See
3.10 REMOVING ENGINE FROM CHASSIS
.
Start
3.13 TOP END OVERHAUL: DISASSEMBLY
. Remove and repair subassembly
components as necessary.
Inspect and repair as necessary. See
3.4 CRANKCASE BREATHING SYSTEM,
XL Models
or
Remove rocker arm outer covers. Remove crankcase breathers. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
Inspect and repair as necessary. See
.
Remove cylinder heads. See
3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder
Inspect and repair as necessary. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Tappet Covers, Pushrod Covers and
Pushrods
Remove pushrods and pushrod covers. See
. Remove tappet covers and tappets. See
END OVERHAUL: ASSEMBLY, Tappets
.
Inspect and repair as necessary. See
Remove cylinders and pistons. See
3.13 TOP END OVERHAUL: DISASSEMBLY,
Inspect upper connecting rod and repair
as necessary. See
PISTON, Connecting Rod Bushings
.
Continue with
3.17 BOTTOM END OVERHAUL: DISASSEMBLY
. Remove and repair
subassembly components as necessary.
Inspect and repair as necessary. See
3.17 BOTTOM END OVERHAUL: DISAS-
SEMBLY, Gearcase Cover and Cam
Gears: XL Models
or
OVERHAUL: DISASSEMBLY, Oil Pump
Housing/Gearcase Cover and Cam Gears:
XR 1200X
.
Remove gearcase cover and cam gears. See
DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models
or
OVERHAUL: DISASSEMBLY, Oil Pump Housing/Gearcase Cover and Cam Gears:
XR 1200X
.
Inspect and repair as necessary. See
or
Remove oil pump. See
or
Inspect and repair as necessary. See
Complete all appropriate steps under
3.17 BOTTOM END OVERHAUL: DISAS-
to split crankcases and remove flywheel assembly, piston jets,
etc.
Inspect and repair transmission assembly
as necessary. See
5.14 TRANSMISSION INSTALLATION
and related subjects.
Complete all appropriate steps under
3.22 BOTTOM END OVERHAUL: ASSEMBLY
Complete all appropriate steps under
3.16 TOP END OVERHAUL: ASSEMBLY
Install engine in motorcycle. Complete all appropriate steps under
Complete motorcycle assembly. See
3.16 TOP END OVERHAUL: ASSEMBLY,
Assembling Motorcycle After Top End Repair
.
2013 Sportster Service: Engine 3-29
3.10
REMOVING ENGINE FROM CHASSIS
PROCEDURE: XL MODELS
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
2.
Remove seat.
3.
Remove left side cover. See
.
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
4.
Disconnect battery. See
.
5.
Drain
primary
chaincase/transmission
fluid.
See
.
6.
Drain oil tank. See
. Do not
install drain plug back in end of drain hose at this time.
7.
Remove O2 sensor connectors [137], [138].
8.
Remove exhaust pipes and mufflers. See
9.
Remove right front footrest assembly and rear brake
linkage.
a.
Models with Mid-mount Controls:
See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
b.
Models with Forward Controls:
See
FOOT CONTROLS: XL FORWARD CONTROLS
10. Remove screw, washer and exhaust pipe clamp bracket
from sprocket cover. Remove two screws securing
sprocket cover to engine case. Remove sprocket cover.
11. Loosen rear axle nut and move rear axle all the way for-
ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt from
transmission sprocket. See
.
12. Remove transmission sprocket. See
13. Remove exhaust system interconnect. See
14. Disconnect oil tank feed, drain and return hoses from oil
tank. Pull drain hose up through drain hose sleeve in rear
of engine crankcase. Remove hose. See
15. Drain fuel tank. Remove fuel tank. See
16. Remove air cleaner assembly.
a.
XL Models except XL 1200V:
See
ASSEMBLY, XL Models except XL 1200V
.
b.
XL 1200V:
See
c.
XL 1200X:
See
d.
EVAP Controlled Models:
Remove EVAP purge
hose from induction module. See
.
17. Remove the horn.
a.
Front Mount:
See
.
b.
Side Mount:
See
.
18. Unplug the following connectors from the induction module:
a.
Fuel injector connectors [84], [85].
b.
TMAP sensor [80].
c.
IAC [87].
d.
TPS [88].
19. Unplug the following electrical connectors from the engine:
a.
Ground wire at powertrain ground stud on crankcase.
b.
Spark plug wires.
c.
Oil pressure switch [120]. See
d.
CKP sensor [79]. See
.
e.
Alternator AC connector [46]. See
.
f.
Neutral indicator switch connector [136]. See
.
g.
VSS [65]. See
h.
Starter relay wire (GN) at starter motor. See
.
i.
ET sensor [90]. Cut the barbed cable strap securing
sensor harness to ECM caddy. Remove the cable
strap. See
20. Disconnect clutch cable. Remove from clutch lever on left
handlebar. Remove cable clips securing clutch cable to
frame left front downtube. See
3-30 2013 Sportster Service: Engine
21. Remove push-in fastener securing right wire harness
caddy to coil bracket. Discard push-in fastener. Remove
screw securing ignition switch to coil bracket. Unplug spark
plug wires from coil. Unplug ignition coil harness connector
[83] from coil. Remove coil and bracket from frame. See
22. Remove screw securing left wire harness caddy to right
wire harness caddy. Separate caddies. See
TRICAL CADDIES, Wire Harness Caddy: XL Models
.
23. Unplug the following harness connectors located in the
wire harness caddies:
a.
Instruments connector [20].
b.
Headlamp connector [38].
c.
Right hand control connector (black) [22].
d.
Left hand control connector (gray) [24].
e.
Front turn signal connector [31].
24. Slide left wire harness caddy between frame and engine,
toward right side of vehicle. Move wire harness caddies
and wiring harnesses out of the way.
25. Remove induction module and intake manifold as a unit.
Secure induction module/intake manifold assembly and
throttle cables out of the way. See
26.
EVAP Controlled Models:
Remove EVAP canister and
disconnect hoses. See
.
27. See
. Remove screws (3, 4), grounding strap
(2), stabilizer link (1) and spacer (5).
28. See
. Remove upper stabilizer link (2) and
brackets (3, 1):
a.
Remove screw (4) securing stabilizer link to engine
bracket (1).
b.
Remove screws (5) and washers (8). Remove horn
bracket (9) (models with front mounted horn) and
upper stabilizer link bracket with stabilizer link.
c.
Remove fasteners (6) and washers (7) and cylinder
head bracket (1).
29. See
. Remove lower stabilizer link (1) and
lower frame bracket (2):
a.
Remove screw (3) securing stabilizer link to engine
crankcase boss.
b.
Remove screws (4), washers (5) and lower frame
bracket with stabilizer link.
30. Remove rider left footrest and mounting bracket assembly
and shift lever.
a.
Models with Mid-mount Controls:
See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
b.
Models with Forward Controls:
See
FOOT CONTROLS: XL FORWARD CONTROLS
5
4
3
2
1
sm03428b
1. Stabilizer link
2. Grounding strap
3. Screw
4. Screw
5. Spacer
Figure 3-14. Rear Stabilizer Link Assembly (typical)
4
7
9
5
8
6
1
2
3
4
sm03439b
1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lockwasher (2)
8. Washer (2)
9. Horn bracket (front mount models)
Figure 3-15. Upper Front Stabilizer Link Assembly
2013 Sportster Service: Engine 3-31
4
5
2
1
3
sm03440a
1. Lower stabilizer link
2. Lower frame bracket
3. Screw (2)
4. Screw (2)
5. Washer (2)
Figure 3-16. Lower Front Stabilizer Link Assembly (typical)
31.
Models with Passenger Footrests:
Remove left pas-
senger footrest and mounting bracket assembly. See
NOTE
Keep reservoir upright. If the reservoir is inverted, bleed the
rear brake. See
32. Remove rear brake master cylinder remote reservoir. Do
not disconnect hose from reservoir. Secure reservoir
upright, out of the way. See
33. Remove rear stop lamp switch from battery tray. Unplug
rear stop lamp switch connectors [121].
34. Remove screw and P-clamp securing rear brake hose to
battery tray.
35. Pull rear stop lamp switch and brake lines out of the way.
Be careful not to bend or kink metal brake lines. See
36. With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).
37. See
. Remove fasteners (13) and J-clip (14)
from each side of frame.
38. Loosen, but do not remove, two front isolator mounting
bracket screws (11) on left side of engine.
39. Loosen, but do not remove, two rear isolator mounting
bracket screws (3) on left side of engine.
40. Attach ENGINE HOOK (Part No. HD-46284) and engine
hoist. Carefully raise engine enough to relieve pressure
from mounting bolts.
41. Remove front engine mount bolt (10) and nut (12).
42. Remove two screws (11) and front isolator mount (9).
43. Remove two rear engine mount/rear fork pivot bolts (1).
Pull rear fork back until fork pivot bosses clear the frame.
44. Remove oil tank vent hose from oil tank. See
45. Remove two screws (3) and rear isolator mounting bracket
(2) from frame.
46. Lift engine as necessary and swing assembly out from
chassis toward the left side. Swing rear of engine out first.
Then remove engine from chassis.
3-32 2013 Sportster Service: Engine
1
2
3
7
6
5
4
8
8
9
10
11
12
14
13
7
1
sm04963a
11.
6.
1.
Screw (2)
Screw (3)
Bolt (2)
2.
12.
7.
Rear isolator mount
Nut
Rear isolator (2)
8.
3.
13.
Front isolator (2)
Screw (2)
Screw
14.
9.
4.
J-clip (2)
Front isolator mount
Rear fork pivot shaft
5.
10.
Rear pivot lockplate
Front mount bolt
Figure 3-17. Engine Mount/Isolator Components (typical)
PROCEDURE: XR 1200X
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Position vehicle upright. Purge the fuel supply hose of high
pressure gasoline. Disconnect fuel supply hose from fuel
pump module. See
.
2.
Remove seat.
3.
Remove left side cover. See
.
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
4.
Disconnect negative (-) battery cable from ground stud on
crankcase. Disconnect positive (+) battery cables at bat-
tery. Remove battery. See
.
5.
Drain
primary
chaincase/transmission
fluid.
See
6.
Drain oil tank. Do not install drain plug back in end of drain
hose at this time. See
.
7.
See
. Remove fasteners (1, 2, 3) and remove
induction module cover. Cut cable strap securing TPS
harness to side plate.
2013 Sportster Service: Engine 3-33
2
1
3
3
sm06774b
1. Fastener, wire form
2. Fastener, to induction module
3. Screws (2)
Figure 3-18. Induction Module Cover: XR 1200X
8.
Disconnect O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers as an assembly. See
.
9.
Remove these parts if present:
EVAP Controlled Models:
Remove EVAP canister and
disconnect hoses. See
.
All other Models:
Remove siren if equipped. See
6.30 SECURITY SYSTEM/OPTIONAL SIREN
10. See
. Remove two fasteners (1) retaining
siren/canister mount plate and brake line (2) retainer.
11. Remove three screws securing sprocket cover to engine
case. Remove sprocket cover.
12. Remove belt guard and debris deflector from rear fork.
13. Remove fastener securing right shock absorber to the rear
fork.
14. Loosen rear axle nut and move rear axle all the way for-
ward. Tighten axle nut enough to hold the axle and wheel
in position in the rear fork. Remove rear drive belt. See
15. Remove transmission sprocket only if transmission or
engine are to be disassembled. See
16. Disconnect rear stop lamp switch connectors [121].
17. Remove rear brake line from clamps at the bottom of left
rear fork.
NOTE
When securing rear master cylinder out of the way in the next
step, make sure to keep the reservoir upright. If the reservoir
is allowed to hang upside down, air bubbles could be introduced
into the rear master cylinder. If this happens, the rear brake
must be bled to remove all air from the hydraulic brake system.
18. See
. Remove fasteners (1) and remove rider's
right footrest including master cylinder assembly and rear
brake linkage. Be careful not to bend or kink metal brake
line and remove assembly out left side of motorcycle. Tie
assembly, with master cylinder upright, out of the way.
19. Disconnect oil tank feed, drain and return hoses from oil
tank. Pull drain hose up through drain hose sleeve in rear
of engine crankcase and remove hose from vehicle. See
.
20. Unplug horn connectors and remove horn from horn
bracket. See
21. Remove fasteners securing air cleaner to fuel tank. Drain
and remove fuel tank. See
22. Remove air cleaner from induction module as an
assembly. See
4.3 AIR CLEANER ASSEMBLY, XR 1200X
23.
EVAP Controlled Models:
Remove EVAP purge hose
from induction module. See
.
24. Unplug the following connectors from the induction module:
a.
Fuel injector connectors [84], [85].
b.
Temperature/Manifold absolute pressure (TMAP)
sensor connector [80].
c.
Idle Air Control (IAC) connector [87].
d.
Throttle Position (TPS) connector [88].
25. Unplug the following electrical connectors from the engine:
a.
Ground wire at powertrain ground stud on crankcase.
b.
Spark plug wires.
c.
Oil pressure switch connector [120]. See
d.
Crank position (CKP) sensor connector [79]. See
6.22 CRANK POSITION SENSOR (CKP)
.
e.
Alternator AC connector [46] and DC connector [77].
See
f.
Neutral indicator switch connector [136]. See
.
g.
Vehicle speed sensor (VSS) connector [65]. See
6.25 VEHICLE SPEED SENSOR (VSS)
.
h.
Starter relay wire (GN) at starter motor. See
.
i.
Engine Temperature (ET) sensor connector [90]. Cut
and remove barbed cable strap securing sensor har-
ness to H-bracket. See
26. If equipped, disconnect jiffy stand sensor connector [133]
and remove sensor. See
27. Disconnect clutch cable and remove from clutch lever on
left handlebar. Remove cable from oil cooler mount and
3-34 2013 Sportster Service: Engine
clips securing clutch cable to left front downtube. See
28. See
. Remove oil cooler fasteners (1) from
frame mounts (2) and remove oil cooler. It is not necessary
to disconnect the oil hoses attached to the oil cooler. Tie
oil cooler to engine.
29. Remove ignition coil. See
30. Position ignition switch out of the way.
31. Remove induction module, leaving cables attached.
Secure induction module assembly and throttle cables out
of the way. See
4.9 INDUCTION MODULE: XR 1200X
.
32. See
. Remove screws (3, 4), grounding strap
(2), stabilizer link (1) and spacer (5).
1
2
sm04977a
1. Fastener, siren/canister mount
2. Rear brake line
Figure 3-19. Siren/Canister Mount Plate and Brake Line
1
2
1
sm04976a
1. Fastener, footrest mount (2)
2. Footrest and master cylinder bracket
Figure 3-20. Right Footrest and Rear Master Cylinder
1
2
sm04953
1. Fastener (2)
2. Oil cooler mount (2)
Figure 3-21. Oil Cooler Mounts
5
4
3
2
1
sm03428b
1. Stabilizer link
2. Grounding strap
3. Screw
4. Screw
5. Spacer
Figure 3-22. Rear Stabilizer Link Assembly (typical)
2013 Sportster Service: Engine 3-35
33. See
. Remove upper stabilizer link (2), cylinder
head stabilizer bracket (1) and the upper frame bracket
(3):
a.
Remove screw (4) securing stabilizer link to cylinder
head bracket (1).
b.
Remove screws (5) and washers (8). Remove horn
bracket (9) and upper stabilizer link bracket (3) with
stabilizer link.
c.
Remove screws (6) and lock washers (7) and the
cylinder head bracket (1).
34. See
. Remove lower stabilizer link (1) and
lower frame bracket (2) as an assembly:
a.
Remove screw (3) securing stabilizer link to engine
crankcase boss.
b.
Remove screws (4), washers (5) and lower frame
bracket with stabilizer link.
35. See
. Remove fastener (1) and disconnect
shift linkage from transmission shift lever.
36. Remove fasteners (2) and remove rider left footrest and
mounting bracket assembly along with foot shift lever and
linkage.
4
7
9
5
8
6
1
2
3
4
sm03439b
1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lockwasher (2)
8. Washer (2)
9. Horn bracket (front mount models)
Figure 3-23. Upper Front Stabilizer Link Assembly
4
5
2
1
3
sm03440a
1. Lower stabilizer link
2. Lower frame bracket
3. Screw (2)
4. Screw (2)
5. Washer (2)
Figure 3-24. Lower Front Stabilizer Link Assembly (typical)
1
2
2
sm06934
1. Fastener, shift linkage
2. Fastener, footrest mount (2)
Figure 3-25. Left Footrest and Shift Linkage
37. With the aid of a FAT JACK (Part No. HD-45968), support
motorcycle on SHOP DOLLY (Part No. HD-45967).
38. See
. Remove fasteners (13) and j-clip (14)
from each side of frame.
39. Loosen, but do not remove, two front isolator mounting
bracket screws (11) on left side of engine.
40. Loosen, but do not remove, two rear isolator mounting
bracket screws (3) on left side of engine.
3-36 2013 Sportster Service: Engine
41. Attach ENGINE HOOK (Part No. HD-46284) and engine
hoist. Carefully raise engine enough to relieve pressure
from mounting bolts.
42. Remove front engine mount bolt (10) and nut (12).
43. Remove two screws (11) and front isolator mount (9).
44. Remove two rear engine mount/rear fork pivot bolts (1).
Pull rear fork back until fork pivot bosses clear the frame.
45. Remove oil tank vent hose from oil tank. See
46. Remove two screws (3) and rear isolator mounting bracket
(2) from frame.
47. Rotate backbone electrical caddy to the left to allow room
to lift the engine.
48. Lift engine as necessary and swing assembly out from left
side of chassis, rear of engine first. Remove engine from
chassis.
1
2
3
7
6
5
4
8
8
9
10
11
12
14
13
7
1
sm04963a
11.
6.
1.
Screw (2)
Screw (3)
Bolt (2)
2.
12.
7.
Rear isolator mount
Nut
Rear isolator (2)
8.
3.
13.
Front isolator (2)
Screw (2)
Screw
14.
9.
4.
J-clip (2)
Front isolator mount
Rear fork pivot shaft
5.
10.
Rear pivot lockplate
Front mount bolt
Figure 3-26. Engine Mount/Isolator Components (typical)
2013 Sportster Service: Engine 3-37
3.11
INSTALLING ENGINE IN CHASSIS
PROCEDURE: XL MODELS
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
TORQUE VALUE
FASTENER
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount, front, screw
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount, rear, screw
81.4-95.0 Nm
60-70 ft-lbs
Fork, rear, pivot/engine mount
bolt
129-142 Nm
95-105 ft-lbs
Engine mount, front, bolt
8.1-13.6 Nm
72-120
in-lbs
Stop lamp switch bracket
screw
3.4-4.5 Nm
30-40
in-lbs
Brake hose clamp to frame,
rear, screw
2.3-2.8 Nm
20-25
in-lbs
Brake master cylinder reser-
voir, rear, mounting screw
61.0-67.8 Nm
45-50 ft-lbs
Footrest mount fastener
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, lower, frame
bracket mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
74.6-88.2 Nm
55-65 ft-lbs
Stabilizer link cylinder head
bracket
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
4.0-5.1 Nm
34-45
in-lbs
Ignition switch mounting screw
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket
screw
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
1.
See
. Make sure pivot shaft (4) and rear pivot
lockplate (5) are mounted on engine mounting boss at
rear of engine. Position right rear isolator (7) on pivot shaft
on rear of engine. Do not Install left rear isolator at this
time.
2.
Position right front isolator (8) on front of engine. Do not
Install left front isolator at this time.
3.
Attach ENGINE HOOK (Part No. HD-46284) and engine
hoist to engine.
4.
Lift engine and swing assembly into chassis from left side.
Swing front of engine in first.
5.
Install left rear isolator (7) over pivot shaft (4). Install rear
isolator mount (2) over left rear isolator and attach to frame
with two screws (3). Do not tighten screws at this time.
6.
Raise or lower engine until right front isolator lines up with
mounting hole in frame.
7.
Install left front isolator (8) and front isolator mount (9) to
left side of frame with two screws (11). Do not tighten
screws at this time.
8.
Insert front engine mount bolt (10) from left side, through
isolators and crankcase boss. Place nut (12) on bolt but
do not tighten at this time.
9.
Tighten two screws (11) securing front isolator mount (9)
to 25-35 ft-lbs (33.9-47.5 Nm).
10. Tighten two screws (3) securing rear isolator mount (2) to
25-35 ft-lbs (33.9-47.5 Nm).
11. Using
new
hose clamp, install oil tank vent hose at oil
tank. See
12. Install rear fork with pivot/engine mount bolts (1). Tighten
to 60-70 ft-lbs (81.4-95.0 Nm).
13. Tighten front engine mount bolt (10) and nut (12) to 95-
105 ft-lbs (129-142 Nm).
14. Remove ENGINE HOOK (Part No. HD-46284).
15. With the aid of a FAT JACK (Part No. HD-45968), remove
motorcycle from SHOP DOLLY (Part No. HD-45967).
16. Install stop lamp switch and brake lines.
a.
Carefully move the stop lamp switch and brake lines
into place.
b.
Secure switch assembly to battery tray with bolt.
Tighten to 72-120
in-lbs
(8.1-13.6 Nm).
c.
Secure flexible brake hose to battery tray with p-clamp
and screw. Tighten to 30-40
in-lbs
(3.4-4.5 Nm).
d.
Plug rear stop lamp switch connectors [121] into rear
stop lamp switch. See
17. Install rear brake master cylinder remote reservoir. Secure
with screw with captive washer. Tighten to 20-25
in-lbs
(2.3-2.8 Nm). Install reservoir cover. See
BRAKE MASTER CYLINDER RESERVOIR
.
18.
Models with Passenger Footrests:
Install left passenger
footrest assembly. Tighten mounting screws to 45-50 ft-
lbs (61.0-67.8 Nm). See
19. Install shift lever and rider left footrest and mounting
bracket assembly:
a.
Models with Mid-mount Controls:
See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
.
b.
Models with Forward Controls:
See
FOOT CONTROLS: XL FORWARD CONTROLS
.
3-38 2013 Sportster Service: Engine
NOTE
Check each end of the stabilizer links for excessive wear prior
to installation. The spherical ball end may rotate loosely, but
should not have any lateral movement. Replace the link if lateral
movement exists.
20. See
. Install lower front stabilizer link and frame
bracket:
a.
Install lower frame bracket (2) with stabilizer link (1).
Secure with screws (4) and washers (5). Tighten to
25-35 ft-lbs (33.9-47.5 Nm).
b.
Install screw (3) securing stabilizer link to engine
crankcase boss. Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
21. See
. Install upper stabilizer link (2), upper
frame bracket (3) and cylinder head bracket (1) :
a.
Install stabilizer link bracket to front head with two
screws and lockwashers. Tighten to 55-65 ft-lbs (74.6-
88.2 Nm).
b.
Install upper frame bracket with stabilizer link, horn
bracket (9) (models with front mounted horn), screws
(5) and washers (8). Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
c.
Install screw (4) securing stabilizer link to engine
bracket (1). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
22. See
. Install spacer (5), rear stabilizer link (1),
grounding strap (2) and screws (3, 4). Tighten to 25-35 ft-
lbs (33.9-47.5 Nm).
NOTE
XL Models: Verify that the EVAP canister mounting hardware
does not contact the rear stabilizer ground strap.
23.
EVAP Controlled Models:
Install EVAP canister and
hoses. See
4.20 EVAPORATIVE EMISSIONS CONTROL
24. Install induction module and intake manifold. See
4.8 INDUCTION MODULE: XL MODELS
.
25. Position left and right wire harness caddies on either side
of frame backbone. Plug in the following connectors, loc-
ated in the caddies:
a.
Instruments connector [20].
b.
Headlamp connector [38].
c.
Right hand control connector (black) [22].
d.
Left hand control connector (gray) [24].
e.
Front turn signal connector [31].
26. Mount caddies together. Verify tabs on caddies engage
each other and frame backbone bracket. Secure with
screw. See
27. Position ignition coil and bracket on frame behind steering
head. Position the wiring harnesses, the right wire harness
caddy and the throttle cables between the coil bracket
uprights.
28. Plug ignition coil harness connector [83] into coil. See
. Mount ignition switch to coil bracket
with screw. Tighten screw to 34-45
in-lbs
(4.0-5.1 Nm).
Secure right wire harness caddy to coil bracket with new
push-in fastener.
29. Connect clutch cable to clutch lever on handlebar. Attach
clutch cable (along with wiring harness and front O2 sensor
harness) to frame front left downtube with cable clips.
Adjust clutch. See
30. Plug the following electrical connectors into the engine:
a.
Engine Temperature (ET) sensor connector [90].
Secure sensor harness to ECM caddy with barbed
cable strap. To avoid damage to sensor during vehicle
operation, secure harness with a loop between sensor
and ECM caddy. Press barbed prong of cable strap
into hole in boss in ECM caddy. See
.
b.
Starter relay wire (GN) at starter motor. See
.
c.
Vehicle speed sensor (VSS) connector [65]. See
6.25 VEHICLE SPEED SENSOR (VSS)
.
d.
Neutral indicator switch connector [136]. See
.
e.
Alternator AC connector [46]. See
.
f.
Crank position (CKP) sensor connector [79]. See
6.22 CRANK POSITION SENSOR (CKP)
.
g.
Oil pressure switch connector [120]. See
h.
Spark plug wires.
i.
Ground wire at powertrain ground stud on crankcase.
31. Connect the following connectors to the induction module.
See
4.8 INDUCTION MODULE: XL MODELS
.
a.
Throttle position sensor (TPS) connector [88].
b.
Idle air control (IAC) connector [87].
c.
Temperature/manifold absolute pressure (TMAP)
sensor connector [80].
d.
Fuel injector connectors [84], [85].
32. Install horn. See
33. Install air cleaner assembly.
a.
XL Models except XL 1200V:
See
ASSEMBLY, XL Models except XL 1200V
.
b.
XL 1200V:
See
c.
EVAP Controlled Models:
Install EVAP purge hose
on induction module. See
.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)
2013 Sportster Service: Engine 3-39
34. Install fuel tank and screw. Tighten to 15-20 ft-lbs (20.4-
27.1 Nm). Attach quick-connect fitting on fuel line to fuel
tank fitting. Gently tug on quick-connect fitting to make
sure it is securely locked in place. See
35. Route oil drain hose down through drain hose sleeve in
rear of engine crankcase. Using new hose clamps, install
oil tank feed, drain and return hoses onto oil tank. Install
drain plug in end of drain hose. Secure with worm drive
clamp. Tighten clamp securely. See
36. Install exhaust system interconnect. See
37. Install transmission sprocket. See
38. Install rear drive belt and hand-tighten rear axle. Final belt
adjustment will be performed later. See
.
39. Install sprocket cover. Secure with two screws. Note that
long screw goes in top hole, short screw in bottom hole.
Do not tighten screws at this time.
40. Install exhaust pipe clamp bracket, washer and screw to
sprocket cover. Tighten to 30-33 ft-lbs (40.7-44.8 Nm).
Now tighten other two sprocket cover screws to 80-120
in-lbs
(9.0-13.6 Nm).
41. Install right front footrest assembly and rear brake linkage.
a.
Models with Mid-mount Controls:
See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
b.
Models with Forward Controls:
See
FOOT CONTROLS: XL FORWARD CONTROLS
42. Install exhaust pipes and mufflers. Plug in O2 sensor
connectors [137], [138]. Route the rear O2 sensor harness
toward left side of motorcycle. Loop the harness back to
the harness connector. The harness cannot contact the
exhaust pipe or port. See
.
43. Fill oil tank. See
1.6 ENGINE OIL AND FILTER, Changing
44. Fill primary chaincase/transmission with FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT. See
.
45. Adjust belt tension and rear wheel alignment. Tighten rear
axle nut to 95-105 ft-lbs (129-142 Nm). Install
new
E-clip.
See
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
46. Connect battery. See
47. Install left side cover. See
.
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)
48. Install seat.
3-40 2013 Sportster Service: Engine
PROCEDURE: XR 1200X
TOOL NAME
PART NUMBER
SHOP DOLLY
HD-45967
FAT JACK
HD-45968
ENGINE HOOK
HD-46284
TORQUE VALUE
FASTENER
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount, front, screw
33.9-47.5 Nm
25-35 ft-lbs
Isolator mount, rear, screw
81.4-95.0 Nm
60-70 ft-lbs
Fork, rear, pivot/engine mount
bolt
129 -142 Nm
95-105 ft-lbs
Engine mount, front, bolt
61.0-67.8 Nm
45-50 ft-lbs
Retainer plate, lower front,
fastener
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, lower, frame
bracket, front, mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
74.6-88.2 Nm
55-65 ft-lbs
Stabilizer link cylinder head
bracket
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, upper front,
frame bracket mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link screw
61.0-67.8 Nm
45-50 ft-lbs
Footrest mount fastener
13.6-20.3 Nm
120-180
in-lbs
Shift linkage pivot bolt
4.0-5.1 Nm
34-45
in-lbs
Ignition switch mounting screw
4.1-6.8 Nm
36-60
in-lbs
Oil cooler fastener: XR 1200X
27.1-32.5 Nm
20-24 ft-lbs
Induction module cover to cyl-
inder head fastener: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Induction module cover to
induction module fastener: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Induction module cover to wire
form fastener: XR 1200X
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
61.0-67.8 Nm
45-50 ft-lbs
Footrest mount fastener
23.0-29.8 Nm
17-22 ft-lbs
Siren/canister bracket rear
brake line fastener
61.0-67.8 Nm
45-50 ft-lbs
Shock absorber mounting bolt
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
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
1.
See
. Verify pivot shaft (4) and rear pivot
lockplate (5) are mounted on engine mounting boss at
rear of engine. Position right rear isolator (7) on pivot shaft
on rear of engine. Do not install left rear isolator at this
time.
2.
Position right front isolator (8) on front of engine. Do not
install left front isolator at this time.
3.
Attach ENGINE HOOK (Part No. HD-46284) and engine
hoist to engine.
4.
Lift engine and swing assembly into chassis from left side.
Swing front of engine in first.
5.
Install left rear isolator (7) over pivot shaft (4). Install rear
isolator mount (2) over left rear isolator and attach to frame
with two screws (3). Do not tighten screws at this time.
6.
Raise or lower engine until right front isolator lines up with
mounting hole in frame.
7.
Install left front isolator (8) and front isolator mount (9) to
left side of frame with two screws (11). Do not tighten
screws at this time.
8.
Insert front engine mount bolt (10) from left side, through
isolators and crankcase boss. Place nut (12) on bolt but
do not tighten at this time.
9.
Tighten two screws (11) securing front isolator mount (9)
to 25-35 ft-lbs (33.9-47.5 Nm).
10. Tighten two screws (3) securing rear isolator mount (2) to
25-35 ft-lbs (33.9-47.5 Nm).
11. Using
new
hose clamp, install oil tank vent hose at oil
tank. See
12. Install rear fork with pivot/engine mount bolts (1). Tighten
to 60-70 ft-lbs (81.4-95.0 Nm).
13. Tighten front engine mount bolt (10) and nut (12) to 95-
105 ft-lbs (129 -142 Nm).
14. Install J-clip (14) to each side of frame. Tighten fasteners
(13) to 45-50 ft-lbs (61.0-67.8 Nm).
15. Remove ENGINE HOOK (Part No. HD-46284).
16. With the aid of a FAT JACK (Part No. HD-45968), remove
motorcycle from SHOP DOLLY (Part No. HD-45967).
17. See
. Install lower front stabilizer link and frame
bracket:
a.
Install lower frame bracket (2) with stabilizer link (1).
Secure with screws (4) and washers (5). Tighten to
25-35 ft-lbs (33.9-47.5 Nm).
b.
Install screw (3) securing stabilizer link to engine
crankcase boss. Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
18. See
. Install cylinder head stabilizer link bracket
(1), upper stabilizer link (2) and upper frame bracket (3):
a.
Install the fasteners (6), lockwashers (7) and the sta-
bilizer cylinder head bracket (1). Tighten to 55-65 ft-
lbs (74.6-88.2 Nm).
b.
Install upper frame bracket with stabilizer link, horn
bracket (9) (models with front mounted horn), screws
(5) and washers (8). Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
c.
Install screw (4) securing stabilizer link to cylinder
head bracket (1). Tighten to 25-35 ft-lbs (33.9-47.5
Nm).
2013 Sportster Service: Engine 3-41
19. See
. Install spacer (5), rear stabilizer link (1),
grounding strap (2) and screws (3, 4). Tighten to 25-35 ft-
lbs (33.9-47.5 Nm).
20. See
. Install shift lever and rider left footrest
and mounting bracket assembly. Tighten fasteners (2) to
45-50 ft-lbs (61.0-67.8 Nm).
21. Connect shift linkage to transmission shift lever. Tighten
fastener (1) to 120-180
in-lbs
(13.6-20.3 Nm).
22. Install induction module and intake manifold. See
4.9 INDUCTION MODULE: XR 1200X
.
23. Rotate backbone wire harness caddy down into place.
24. See
. Position ignition coil and bracket
on backbone caddy behind steering head. Place front wire
harnesses, mounting boss from right wire harness caddy
and throttle cables between coil bracket uprights.
25. Plug ignition coil harness connector [83] into coil. Mount
ignition switch to coil bracket with screw. Tighten to 34-45
in-lbs
(4.0-5.1 Nm). Secure right wire harness caddy to
coil bracket with new push-in fastener.
26. Connect clutch cable to clutch lever on handlebar. Secure
cable to lower oil cooler mount. Attach clutch cable (along
with wiring harness and front O2 sensor harness) to frame
front left downtube with cable clips. Adjust clutch. See
27. See
. Install the oil cooler to the frame mounts.
Tighten fasteners (1) to 36-60
in-lbs
(4.1-6.8 Nm).
28. Plug the following electrical connectors into the engine:
a.
Engine Temperature (ET) sensor connector [90].
Secure sensor harness to H-bracket with barbed cable
strap. To avoid damage to sensor during vehicle
operation, secure harness with a loop between sensor
and H-bracket. Press barbed prong of cable strap into
hole in boss in H-bracket. See
b.
Starter relay wire (GN) at starter motor. See
.
c.
Vehicle speed sensor (VSS) connector [65]. See
6.25 VEHICLE SPEED SENSOR (VSS)
.
d.
Neutral indicator switch connector [136]. See
.
e.
Alternator AC connector [46]. Secure to right down-
tube with a cable strap. See
.
f.
Connect voltage regulator DC connector [77] and
secure to frame cross member with cable strap. See
g.
Crank position (CKP) sensor connector [79]. See
6.22 CRANK POSITION SENSOR (CKP)
.
h.
Oil pressure switch connector [120]. See
i.
Spark plug wires.
j.
Ground wire at powertrain ground stud on crankcase.
29. See
4.9 INDUCTION MODULE: XR 1200X
and plug the
following into the induction module:
a.
TPS [88].
b.
IAC [87].
c.
TMAP [80].
d.
Fuel injector connectors [84], [85].
30. Install and connect jiffy stand sensor. See
STAND SENSOR (JSS): INTERNATIONAL MODELS
31. Install and connect horn. See
32. See
. Install induction module cover. Secure
TPS harness to cover during installation.
a.
Tighten fasteners (2) to 20-24 ft-lbs (27.1-32.5 Nm).
b.
Tighten fastener (1) to 84-108
in-lbs
(9.5-12.2 Nm).
c.
Tighten fastener (3) to 84-108
in-lbs
(9.5-12.2 Nm).
33. Install air cleaner assembly on induction module. Connect
breather hoses to rocker box fittings. See
.
34. EVAP Controlled Models: Install EVAP purge hose on
induction module. See
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)
35. Install fuel tank. Tighten screws to 15-20 ft-lbs (20.4-27.1
Nm). Attach quick-connect fitting on fuel line to fuel tank
fitting. Gently tug on quick-connect fitting to make sure it
is securely locked in place. See
36. Secure air filter assembly to fuel tank with two screws.
37. Install oil hoses.
a.
Feed oil drain hose down through drain hose sleeve
in rear of engine crankcase.
b.
Using
new
hose clamps, install oil tank feed, drain
and return hoses onto oil tank.
c.
Install drain plug in end of drain hose.
d.
Secure with worm drive clamp. Tighten clamp
securely. See
38. See
. Install right rider footrest assembly and
rear master cylinder assembly. Tighten fasteners (1) to
45-50 ft-lbs (61.0-67.8 Nm).
39. See
. Secure brake line and siren/canister
mount plate to frame and rear fork. Tighten fasteners (1)
to 17-22 ft-lbs (23.0-29.8 Nm). Connect rear stop lamp
switch connectors.
NOTE
Verify that the EVAP canister mounting hardware does not
contact the rear stabilizer ground strap.
3-42 2013 Sportster Service: Engine
40. Install these parts if present:
a.
EVAP Controlled Models:
Install EVAP canister and
hoses. See
4.20 EVAPORATIVE EMISSIONS CON-
.
b.
All other Models:
Install siren if equipped. See
6.30 SECURITY SYSTEM/OPTIONAL SIREN
41. If
removed,
install
transmission
sprocket.
See
.
42. Install rear drive belt and hand-tighten rear axle. Final belt
adjustment will be performed later. See
.
43. Secure right shock absorber to rear fork. Tighten to 45-
50 ft-lbs (61.0-67.8 Nm).
44. Install belt guard and debris deflector.
45. Install sprocket cover. Tighten sprocket cover screws.
a.
Tighten rear (larger) screw to 30-33 ft-lbs (40.7-44.8
Nm).
b.
Tighten forward and lower (smaller) screws to 80-120
in-lbs
(9.0-13.6 Nm).
46. Install exhaust pipes and mufflers. See
NOTE
It is important to route and secure the front O2 sensor harness
correctly
to
prevent
premature
harness
failure.
See
4.12 OXYGEN (O2) SENSOR, Installation
47. Plug in O2 sensor connectors [137], [138]. Make sure each
O2 sensor harness is routed and secured correctly. See
4.12 OXYGEN (O2) SENSOR, Installation
48. Fill oil tank. See
1.6 ENGINE OIL AND FILTER, Changing
.
49. Fill primary chaincase/transmission with FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT. See
50. Adjust belt tension and rear wheel alignment. Tighten rear
axle nut to 95-105 ft-lbs (129-142 Nm). Install
new
E-clip.
See
51. Connect battery. See
.
52. Install left side cover. See
.
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)
53. Install seat.
2013 Sportster Service: Engine 3-43
3.12
PRECISION COOLING SYSTEM: XR 1200X
GENERAL
TOOL NAME
PART NUMBER
OIL LINE REMOVER, 1/2 INCH
HD-46503
OIL LINE REMOVER, 3/8 INCH
HD-49096
See
. The oil lines used in the Precision Cooling
System incorporate flanged oil lines and quick connect fittings.
Quick connect fittings can be separated using either the OIL
LINE REMOVER, 1/2 INCH (Part No. HD-46503) or OIL LINE
REMOVER, 3/8 INCH (Part No. HD-49096).
1.
Close the OIL LINE REMOVER over the oil line. Match
the notches in the tool flange to the U-bends in the retainer
clip.
2.
Rotate the tool to expand the spring clip.
3.
Use finger and thumb to hold the OIL LINE REMOVER
squarely against the fitting to keep the spring clip
expanded. Use only enough pressure to hold the tool
square. Excess pressure will prevent simultaneously
pulling the line and tool from the fitting.
4.
Pull the oil line and the tool from the fitting.
5.
Apply a light film of clean engine oil to the oil line. This
eases assembly and prevents damage to the connector
O-ring.
6.
To assemble, push the oil line squarely into quick connect
fitting to connect.
sm07584
Figure 3-27. Flanged Oil Line and Remover
RETURN OIL MANIFOLD
TOOL NAME
PART NUMBER
OIL LINE REMOVER, 3/8 INCH
HD-49096
TORQUE VALUE
FASTENER
9.5-12.2 Nm
84-108
in-lbs
Return oil manifold screw: XR
1200X
Removal
1.
Disconnect and remove battery. See
2.
Remove exhaust system. See
.
3.
Drain oil tank. See
4.
Remove oil drain hose from sleeve in rear engine crank-
case.
5.
Remove battery positive (+) cable from starter motor. See
.
6.
See
. From right side of motorcycle, remove
fastener (1) securing oil manifold.
7.
See
. Disconnect oil return hose (2) from oil
tank.
8.
Remove rear cylinder head oil line (1) from quick connect
fitting using OIL LINE REMOVER, 3/8 INCH (Part No. HD-
49096) while sliding return oil manifold back off from rigid
oil lines and remove assembly from engine.
1
2
sm06543a
1. Rear cylinder head oil line
2. Return oil hose to tank
Figure 3-28. Rear Cylinder Oil Line
3-44 2013 Sportster Service: Engine
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