Harley Davidson 2013 Sportster Models. Service Manual - page 1

MAINTENANCE

1.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................1-1

1.2 GENERAL

Servicing a New Motorcycle...............................................1-3
Safe Operating Maintenance..............................................1-3
Shop Practices....................................................................1-3

Repair Notes................................................................1-3
Safety..........................................................................1-3
Removing Parts...........................................................1-3
Cleaning......................................................................1-3
Disassembly and Assembly........................................1-4
Checking Torques on Fasteners..................................1-4
Magnetic Parts Trays...................................................1-4

Repair and Replacement Procedures................................1-4

Hardware and Threaded Parts....................................1-4
Threadlocking Agents..................................................1-4
Wiring, Hoses and Lines.............................................1-4
Instruments and Gauges.............................................1-4
Bearings......................................................................1-4
Bushings......................................................................1-4
Gaskets.......................................................................1-4
Lip-Type Seals.............................................................1-4
O-Rings.......................................................................1-5
Gears...........................................................................1-5
Shafts..........................................................................1-5
Part Replacement........................................................1-5

Cleaning..............................................................................1-5

Part Protection.............................................................1-5
Cleaning Process........................................................1-5
Rust or Corrosion Removal.........................................1-5
Bearings......................................................................1-5

Tool Safety..........................................................................1-5

Air Tools.......................................................................1-5
Wrenches....................................................................1-5
Pliers/Cutters/Pry Bars................................................1-6
Hammers.....................................................................1-6
Punches/Chisels..........................................................1-6
Screwdrivers................................................................1-6
Ratchets and Handles.................................................1-6
Sockets........................................................................1-6
Storage Units...............................................................1-6

1.3 FUEL AND OIL

Fuel.....................................................................................1-7
Gasoline Blends..................................................................1-7
Engine Lubrication..............................................................1-7
Winter Lubrication...............................................................1-8

1.4 BULB REQUIREMENTS

Bulb Chart...........................................................................1-9

1.5 MAINTENANCE SCHEDULE

General.............................................................................1-10

1.6 ENGINE OIL AND FILTER

Checking and Adding Oil..................................................1-15

Removing and Replacing Oil Filler Cap....................1-15
Oil Level Cold Check.................................................1-15
Oil Level Hot Check...................................................1-16

Changing Oil and Filter.....................................................1-16

Draining Oil Tank.......................................................1-16
Removing Oil Filter....................................................1-17

Installing Oil Filter......................................................1-17
Refilling Oil Tank........................................................1-18

1.7 AIR FILTER

XL Models except XL 1200V............................................1-19

Removal....................................................................1-19
Installation.................................................................1-19

XL 1200V..........................................................................1-19

Removal....................................................................1-19
Installation.................................................................1-20

XR 1200X.........................................................................1-20

Removal....................................................................1-20
Installation.................................................................1-21

Cleaning Filter Element....................................................1-22

1.8 TIRES AND WHEELS

Air Pressure......................................................................1-23
Tire Replacement.............................................................1-23

Tread Wear................................................................1-23
Tire Damage..............................................................1-24

Specified Tires..................................................................1-24
Wheel Bearings................................................................1-24
Wheel Spokes...................................................................1-24

Identify Wheel Spoke Groups....................................1-25
Wheel Spoke Adjustment..........................................1-25

1.9 PRIMARY CHAIN

Free Play Adjustment.......................................................1-26

1.10 TRANSMISSION LUBRICANT

Transmission Lubrication..................................................1-27

Check Lubricant Level...............................................1-27
Change Lubricant......................................................1-28

1.11 CLUTCH

Adjustment........................................................................1-29

Release the Clutch Cable Tension............................1-29
Clutch Adjustment.....................................................1-29
Lever Free Play.........................................................1-30

1.12 DRIVE BELT AND SPROCKETS

General.............................................................................1-31
Cleaning............................................................................1-31
Inspection.........................................................................1-31

Sprockets...................................................................1-31
Idler Pulley: XR 1200X..............................................1-31
Drive Belt...................................................................1-31

Drive Belt Deflection.........................................................1-32

Gauging Deflection....................................................1-32
Adjustment.................................................................1-33

1.13 THROTTLE CONTROL

Cable Inspection and Lubrication.....................................1-35
Cable Adjustment.............................................................1-35

Operation...................................................................1-35
Adjustment.................................................................1-35

1.14 CABLE AND CHASSIS LUBRICATION

General.............................................................................1-36
Cables and Hand Levers..................................................1-36
Foot Shift Lever and Rear Brake Pedal............................1-36
Jiffy Stand.........................................................................1-36
Steering Head Bearings....................................................1-36

III

T

ABLE

OF

CONTENTS

1.15 BRAKES

General.............................................................................1-37
Brake Lines.......................................................................1-37
Fluid Level........................................................................1-37
Troubleshooting................................................................1-39

1.16 BRAKE PADS AND DISCS: XL MODELS

Inspection.........................................................................1-40

Brake Pads................................................................1-40
Brake Disc Thickness, Lateral Runout and
Warpage....................................................................1-40

Brake Pad Replacement: Front........................................1-41
Brake Pad Replacement: Rear.........................................1-44

1.17 BRAKE PADS AND DISCS: XR 1200X

Inspection.........................................................................1-47

Brake Pads................................................................1-47
Brake Disc Thickness, Lateral Runout and
Warpage....................................................................1-47

Brake Pad Replacement: Front........................................1-48

Removal....................................................................1-48
Installation.................................................................1-49

Brake Pad Replacement: Rear.........................................1-50

Removal....................................................................1-50
Installation.................................................................1-51

1.18 SPARK PLUGS

Removal............................................................................1-53
Inspection.........................................................................1-53
Cleaning............................................................................1-53
Installation.........................................................................1-53
Spark Plug Cable Inspection............................................1-54

1.19 STEERING HEAD BEARINGS

Fall-Away..........................................................................1-55

Measurement.............................................................1-55
Adjustment.................................................................1-55

Lubrication........................................................................1-55

1.20 CRITICAL FASTENERS

Inspection.........................................................................1-56

Checking Torques on Fasteners................................1-56

1.21 ENGINE MOUNTS AND STABILIZER
LINKS

Inspection.........................................................................1-58

1.22 BATTERY MAINTENANCE

General.............................................................................1-59
Battery Disconnection and Removal................................1-60
Cleaning and Inspection...................................................1-61
Voltmeter Test...................................................................1-61

Voltmeter Test............................................................1-61

Charging Battery...............................................................1-61

Safety Precautions....................................................1-61
Using a Battery Charger............................................1-62

Battery Installation and Connection..................................1-62
Storage.............................................................................1-63

1.23 EXHAUST SYSTEM

Exhaust System Leak Check............................................1-65

1.24 WHEEL ALIGNMENT

Wheel Alignment...............................................................1-66

Checking Wheel Alignment.......................................1-66
Adjusting Wheel Alignment.......................................1-67

1.25 SUSPENSION ADJUSTMENTS

Front Fork: XR 1200X.......................................................1-68

Spring Preload...........................................................1-68
Rebound Damping....................................................1-68
Compression Damping..............................................1-68

Shock Absorber Preload: All Models................................1-69
Shock Absorber Rebound and Compression: XR 1200X..1-70

Shock Absorber Rebound Damping Adjustment.......1-70
Shock Absorber Compression Damping
Adjustment.................................................................1-70

Suspension Tuning: XR 1200X.........................................1-70

1.26 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-72
Headlamp: Adjustment.....................................................1-72

Adjustment: XL 1200X/C/C ANV/CP/CA/CB/V..........1-72
Adjustment: XL 883R/L/N, XR 1200X.......................1-73

1.27 STORAGE

Placing in Storage.............................................................1-74
Removal From Storage.....................................................1-74

1.28 TROUBLESHOOTING

General.............................................................................1-76
Engine...............................................................................1-76

Starter Motor Does Not Operate or Does Not Turn Engine
Over...........................................................................1-76
Engine Turns Over But Does Not Start.....................1-76
Starts Hard................................................................1-76
Starts But Runs Irregularly or Misses........................1-76
Spark Plug Fouls Repeatedly....................................1-76
Pre-Ignition or Detonation (Knocks or Pings)............1-77
Check Engine Light Illuminates During Operation.....1-77
Overheating...............................................................1-77
Valve Train Noise.......................................................1-77
Excessive Vibration...................................................1-77

Lubrication System...........................................................1-77

Oil Does Not Return To Oil Tank...............................1-77
Engine Uses Too Much Oil Or Smokes Excessively..1-77
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc.............................................................................1-77
Low Oil Pressure.......................................................1-77
High Oil Pressure......................................................1-78

Electrical System..............................................................1-78

Alternator Does Not Charge......................................1-78
Alternator Charge Rate Is Below Normal..................1-78
Speedometer Operates Erratically............................1-78

Transmission....................................................................1-78

Shifts Hard.................................................................1-78
Jumps Out Of Gear...................................................1-78
Clutch Slips................................................................1-78
Clutch Drags Or Does Not Release..........................1-78
Clutch Chatters..........................................................1-78

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Handling............................................................................1-78
Brakes...............................................................................1-78

Brake Does Not Hold Normally.................................1-78

CHASSIS

2.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Tables.................................................................................2-9

Chassis........................................................................2-9
Wheels and Tires.......................................................2-11

2.3 VEHICLE IDENTIFICATION NUMBER
(VIN)

Vehicle Identification Number (VIN)..................................2-12

General......................................................................2-12
Location.....................................................................2-12
Abbreviated VIN........................................................2-12

2.4 TIRES

Removal............................................................................2-14
Cleaning, Inspection and Repair......................................2-14
Installation.........................................................................2-14

Mounting....................................................................2-14
Tube Type Tires.........................................................2-14
Tubeless Tires...........................................................2-15

Checking Tire Runout.......................................................2-15

Lateral Runout...........................................................2-15
Radial Runout............................................................2-16

Wheel Balancing...............................................................2-16

Static vs Dynamic......................................................2-16
Weights......................................................................2-16

2.5 WHEELS

General.............................................................................2-18
Wheel Bearing End Play...................................................2-18
Front Wheel......................................................................2-19

Removal....................................................................2-19
Disassembly: Cast Front Wheel................................2-19
Assembly Cast Single Disc.......................................2-20
Assembly Cast Dual Disc: XL 883R..........................2-21
Assembly Cast Dual Disc: XR 1200X........................2-22
Disassembly: Laced Front Wheel..............................2-22
Assembly: Laced Front Wheel..................................2-22
Installation.................................................................2-22

Rear Wheel.......................................................................2-23

Removal....................................................................2-23
Disassembly..............................................................2-23
Cleaning and Inspection............................................2-24
Assembly...................................................................2-24
Installation.................................................................2-25

Sealed Wheel Bearings....................................................2-25

Inspection..................................................................2-25
Removal....................................................................2-25
Installation.................................................................2-27

2.6 WHEEL LACING

Wheel Lacing: Angle Flange Hub.....................................2-28
Wheel Lacing: Straight Flange Hub, Single Hole Circle....2-29

Wheel Lacing: Straight Flange Hub, Dual Hole Circle......2-31

2.7 CHECKING AND TRUING WHEELS

Cast Wheel Runout...........................................................2-33

Wheel Stand..............................................................2-33
Lateral Runout...........................................................2-33
Radial Runout............................................................2-33

Laced Wheel Rim Offset...................................................2-33
Truing Laced Wheels........................................................2-35

Radial Runout............................................................2-35
Lateral Runout...........................................................2-35

2.8 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-37
Inspection.........................................................................2-37
Removal............................................................................2-37
Disassembly.....................................................................2-39
Cleaning, Inspection and Repair......................................2-41
Assembly..........................................................................2-41
Installation.........................................................................2-42

2.9 FRONT BRAKE CALIPER: XL MODELS

Removal............................................................................2-45
Disassembly.....................................................................2-46
Cleaning, Inspection and Repair......................................2-48
Assembly..........................................................................2-49
Lubricating Front Caliper Bolt Pins and Boots..................2-49
Installing Brake Pads in Caliper........................................2-50
Installation.........................................................................2-51

2.10 FRONT BRAKE CALIPER: XR 1200X

Removal............................................................................2-53
Disassembly.....................................................................2-54
Cleaning, Inspection and Repair......................................2-55
Assembly..........................................................................2-56
Installation.........................................................................2-57

2.11 REAR BRAKE MASTER CYLINDER: XL
MODELS

General.............................................................................2-58
Inspection.........................................................................2-58
Removal............................................................................2-58
Disassembly.....................................................................2-59
Cleaning and Inspection...................................................2-60
Assembly..........................................................................2-61
Installation.........................................................................2-62

2.12 REAR BRAKE MASTER CYLINDER: XR
1200X

General.............................................................................2-64
Inspection.........................................................................2-64
Removal............................................................................2-64
Disassembly.....................................................................2-65
Cleaning, Inspection and Repair......................................2-66
Assembly..........................................................................2-66
Installation.........................................................................2-67

2.13 REAR BRAKE MASTER CYLINDER
RESERVOIR

Removal: XL Models.........................................................2-69

TABLE OF CONTENTS V

TABLE OF CONTENTS

Installation: XL Models......................................................2-70
Removal: XR 1200X.........................................................2-70
Installation: XR 1200X......................................................2-71

2.14 REAR BRAKE CALIPER: XL MODELS

Removal............................................................................2-72
Disassembly.....................................................................2-74
Cleaning, Inspection and Repair......................................2-75
Lubricating Rear Caliper Bolt Pins and Boots..................2-75
Assembly..........................................................................2-76
Installation.........................................................................2-77

2.15 REAR BRAKE CALIPER: XR 1200X

Removal............................................................................2-79
Disassembly.....................................................................2-80
Cleaning, Inspection and Repair......................................2-82
Assembly..........................................................................2-82
Installation.........................................................................2-83

2.16 BRAKE LINES

Front Brake Line...............................................................2-86

Removal....................................................................2-86
Installation.................................................................2-86

Front Brake Line Routing..................................................2-88

XL 883R.....................................................................2-88
XL 883L/N, XL 1200X, XL 1200C/C ANV/CP w/Pull
Back...........................................................................2-88
XL 1200V/CP/CB w/Mini-Ape....................................2-89
XL 1200CP/CA with Drag Bar...................................2-89
XR 1200X..................................................................2-90

Rear Brake Line: XL Models.............................................2-90

Removal....................................................................2-91
Installation.................................................................2-91

Rear Brake Line: XR 1200X.............................................2-92

Removal....................................................................2-92
Installation.................................................................2-93

2.17 BLEEDING BRAKES

General.............................................................................2-94
Procedure.........................................................................2-94

2.18 LEFT SIDE COVER

General.............................................................................2-96
Opening Left Side Cover..................................................2-96
Closing Left Side Cover....................................................2-97
Removing Left Side Cover................................................2-97
Installing Left Side Cover..................................................2-97

2.19 FRONT FORK: XL MODELS

Changing Fork Oil: XL Models..........................................2-98

Drain Forks: XL 883N/R............................................2-98
Fill Forks: XL 883N/R................................................2-98
Drain Forks: XL 883L and XL 1200X/C/C
ANV/CP/CA/CB/V......................................................2-98

Removal............................................................................2-99
Disassembly.....................................................................2-99

Drain Fork Oil............................................................2-99
Fork Disassembly......................................................2-99

Cleaning, Inspection and Repair......................................2-99
Assembly........................................................................2-101
Fill with Fork Oil..............................................................2-101

Installation.......................................................................2-102

2.20 FRONT FORK: XR 1200X

Removal..........................................................................2-103
Disassembly...................................................................2-103

Initial Disassembly...................................................2-103
Drain the Fork Oil....................................................2-104
Complete Disassembly............................................2-104

Cleaning and Inspection.................................................2-105
Assembly........................................................................2-106

Piston Rod Service..................................................2-106
Initial Assembly........................................................2-106
Fill with Fork Oil.......................................................2-107
Complete Assembly................................................2-108

Installation.......................................................................2-108

2.21 FORK STEM AND BRACKET
ASSEMBLY

Removal and Disassembly.............................................2-109
Cleaning, Inspection and Repair....................................2-110
Assembly and Installation...............................................2-110

2.22 BELT GUARD AND DEBRIS
DEFLECTOR

Belt Guard: XL Models....................................................2-111

Removal..................................................................2-111
Installation...............................................................2-111

Debris Deflector: XL Models...........................................2-111

Removal..................................................................2-111
Installation...............................................................2-111

Belt Guard: XR 1200X....................................................2-111

Removal..................................................................2-111
Installation...............................................................2-111

Debris Deflector: XR 1200X...........................................2-112

Removal..................................................................2-112
Installation...............................................................2-112

2.23 REAR FORK

Removal..........................................................................2-113
Disassembly...................................................................2-113
Cleaning and Inspection.................................................2-114
Assembly........................................................................2-114
Installation.......................................................................2-114

2.24 SHOCK ABSORBERS

Removal..........................................................................2-116
Cleaning and Inspection.................................................2-116
Installation.......................................................................2-116
Shock Disposal: Schrader Valve Models........................2-117

2.25 STABILIZER LINKS

General...........................................................................2-118
Upper Front Stabilizer Link.............................................2-118

Removal..................................................................2-118
Installation...............................................................2-118

Lower Front Stabilizer Link.............................................2-118

Removal..................................................................2-118
Installation...............................................................2-118

Rear Stabilizer Link.........................................................2-119

Removal..................................................................2-119
Installation...............................................................2-119

VI TABLE OF CONTENTS

TABLE OF CONTENTS

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

12. Test ride motorcycle. Repeat the bleeding procedure if

brakes feel spongy.

Table 2-18. Fluid Level

SPECIFICATION

ITEM

Boss or ridge

Front reservoir

Ledge or range window

Rear reservoir

Table 2-19. Torque Specifications

TORQUE

COMPONENT

35-61

in-lbs

(4.0-6.9 Nm)

Bleeder

9-17

in-lbs

(1.0-2.0 Nm)

Front cover

Hand tighten

Rear cover

HOME

2013 Sportster Service: Chassis 2-95

2.18

LEFT SIDE COVER

GENERAL

See

Figure 2-133

. The left side cover provides access to the

battery (1), fuses (3, 4) and diagnostic connector (5).

XL Models:

The left side cover is secured by two barrel clips

secured to two upper slots that fit into socket clips mounted to
the frame.

XR 1200X:

The left side cover is secured by two molded-in

posts that fit into grommets.

The side cover is also secured by a bottom slot that fits onto
a mounting tab on the battery tray.

NOTE

The left side cover does not need to be completely removed
to access the battery or fuses.

5

2

4

3

1

sm06647

1. Battery
2. Positive (+) battery terminal (under protective

rubber boot)

3. Main fuse and holder
4. System fuses and relays
5. Diagnostic connector (data link)

Figure 2-133. Main Fuse and Battery Location: All Models

OPENING LEFT SIDE COVER

1.

Place a clean, dry cloth over rear brake master cylinder
reservoir and left passenger foot peg (if equipped). This
will protect left side cover from damage.

NOTE

On XL models, disengage the rear clip first for easier opening.

2.

See

Figure 2-134

or

Figure 2-135

. Grasp top corners of

side cover. Gently pull away from plastic socket clips (XL
models) or grommets (XR 1200X) on frame.

2

4

1

1

2

3

sm01416a

1. Socket clips (on frame)
2. Side cover barrel clips (top)
3. Mounting tab (on battery tray)
4. Side cover barrel clips mounting screw (bottom)

Figure 2-134. Left Side Cover: XL Models

2

1

1

sm06777

1. Side cover mounting posts (top)
2. Side cover mounting slot (bottom)

Figure 2-135. Left Side Cover: XR 1200X

HOME

2-96 2013 Sportster Service: Chassis

1

3

4

2

1

2

sm01417a

1. Battery tray assembly
2. Mounting tab
3. Side cover (closed)
4. Side cover (open)

Figure 2-136. Left Side Cover Bottom Mount: All Models

3.

See

Figure 2-136

. Rotate top of cover away from motor-

cycle and down slightly. Mounting slot on cover will slide
down mounting tab (2) on battery tray assembly (1). Side
cover (4) will rest on top of rear brake master cylinder
reservoir and left passenger footrest (if equipped).

Leaning or placing tools on side cover could cause damage
to cover and/or mounting tab on battery tray. (00523b)

CLOSING LEFT SIDE COVER

1.

Grasp top corners of side cover. While rotating top of cover
up toward motorcycle, gently pull cover up so that
mounting slot slides up mounting tab.

2.

Press top of side cover into place:

a.

XL models:

See

Figure 2-134

. Line up barrel clips

on side cover with socket clips on motorcycle frame,
aligning with front clip first. Press top of side cover
into clips until you hear an audible snap.

b.

XR 1200X:

See

Figure 2-135

. Line up molded-in posts

in top of side cover with mounting grommets on
motorcycle frame. Press posts in side cover into
grommets until snug.

NOTE

Side cover should snap into place with minimal pressure. Using
excessive force or striking side cover to close it can damage
mounting clips (XL models) or molded-in posts (XR 1200X).

REMOVING LEFT SIDE COVER

1.

See

Figure 2-134

or

Figure 2-135

. Grasp top corners of

side cover. Gently pull away from plastic mounting clips
(XL models) or grommets (XR 1200X) on frame.

NOTE

On XL models, disengage the rear clip first for easier opening.

2.

See

Figure 2-137

. Lift side cover up and tilt cover to the

rear of the motorcycle. With a slight back and forth rocking
motion, pull up gently until cover disengages from
mounting tab on battery tray.

sm01419a

Figure 2-137. Removing Left Side Cover: All Models (XL

Model Shown)

INSTALLING LEFT SIDE COVER

1.

Position side cover over battery tray assembly. Align slot
in bottom of cover to mounting tab on battery tray.

2.

Gently guide the side cover down over mounting tab.

3.

Close the left side cover. See

2.18 LEFT SIDE COVER,

Closing Left Side Cover

.

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2013 Sportster Service: Chassis 2-97