Harley Davidson 2013 Sportster Models. Service Manual

REMOVAL

Remove front brake caliper(s). See

2.9 FRONT BRAKE

CALIPER: XL MODELS

Remove front wheel assembly. See

2.5 WHEELS

Remove front fender mounting screws and locknuts.
Remove fender. See

2.31 FRONT FENDER

See

Figure 2-139

. Loosen, but do not remove, slider tube

caps (1).

Loosen front fork upper and lower bracket pinch screws
(2 and 3). Remove fork assemblies from fork brackets.

sm07586a

1. Slider tube cap
2. Upper pinch bolt
3. Lower pinch bolt

Figure 2-139. Fork Tube Bracket

DISASSEMBLY

Drain Fork Oil

See

Figure 2-141

. Remove tube cap (7) from slider tube

(9). Remove O-ring (6) from tube cap.

Place a pan under the fork. Remove the drain screw and
washer (19) from slider. Drain the fork oil.

Fork Disassembly

See

Figure 2-141

. Remove spring (5) from slider tube.

All except XL 883L and XL 1200X:

Remove spring collar

(20) and spring washer (21) from slider tube.

All except XL 883N:

Remove cover (11).

NOTE

See

Figure 2-144

. The XL 883N is equipped with fork gaiters

(2) instead of metal covers. The lower lip (3) of the gaiter fits
into the groove at the upper end of the slider (1). The upper
end of the gaiter fits tightly around the slider tube, just below
the lower bracket (4).

XL 883N:

See

Figure 2-144

. Peel back lower lip (3) of fork

gaiter (2) from slider groove and slide fork gaiter up and
off end of slider tube.

See

Figure 2-141

. Remove dust seal (12). Compress

internal circle clip (13). Remove clip from groove in top of
slider bore.

Remove screw (18) and washer (17) from bottom of slider.

NOTE

Since there is little resistance to damper tube (3) rotation within
slider tube (9) when removing screw (18), use an air impact
wrench for best results.

Withdraw slider tube (9) from slider until lower bushing
(10) on slider tube contacts upper bushing (1) in slider.

Tap out the oil seal (14), the spacer (2) and the upper
bushing with the lower bushing on the slider.

Remove sleeve (15). Sleeve will be found within slider or
on bottom end of damper tube (3).

10. Insert a small diameter rod through opening in bottom of

slider tube to remove damper tube assembly.

11. Remove rebound spring (8) from damper tube.

12. Remove damper tube ring(s) (4) from damper tube.

13. Remove lower bushing from damper tube only if replace-

ment is necessary.

CLEANING, INSPECTION AND REPAIR

Thoroughly clean and inspect all parts. Replace as
necessary.

See

Figure 2-140

. Inspect the O-ring (6) for damage, wear

or general deterioration. Replace as necessary.

Replace all other removed seals.

Inspect damper tube ring(s) (4). Replace as necessary.

Check dust seal (12) where it contacts slider tube (9). Dust
seal should provide continuous contact against slider tube
and should not show excessive wear.

Check slider tube where it is contacted by seal. Tube
surface should be shiny, smooth and free of scoring or
abrasions.

Verify small hole in lower end of slider tube groove is
unobstructed.

HOME

2013 Sportster Service: Chassis 2-99

sm06850a

15.

Sleeve

Upper bushing

16.

Spacer

Pinch bolt

17.

Washer

Damper tube

18.

Damper tube ring

Screw

19.

Drain screw and washer (XL 883N/R)

Spring

20.

O-ring

Spring collar (all except XL 883L and XL 1200X)

21.

Spring washer (all except XL 883L and XL 1200X)

Tube cap

22.

Rebound spring

Fork gaiter (XL 883N)

23.

Washer

Slider tube

10.

24.

Lower bushing

Lockwasher

25.

11.

Nut

Cover (all except XL 883N)

12.

26.

Dust seal

Sliders (RH and LH XL 883L/N and 1200V/C/C
ANV/CP/CA/CB)

13. Internal circle clip

27.

14.

Sliders (RH and LH XL 883R)

Oil seal

28. Sliders (RH and LH XL 1200X)

Figure 2-140. Front Slider Tube/Slider Assembly: XL Models

HOME

2-100 2013 Sportster Service: Chassis

ASSEMBLY

TOOL NAME

PART NUMBER

FORK SEAL AND BUSHING
INSTALLATION TOOL

HD-36583

TORQUE VALUE

FASTENER

14.9-24.4 Nm

132-216

in-lbs

Fork slider tube fastener: XL
Models

See

Figure 2-140

. If lower bushing (10) was removed,

install

new

lower bushing in groove of slider tube (9).

Expand bushing only enough to fit over tube.

Install damper tube ring(s) (4) into groove(s) of damper
tube (3).

Place rebound spring (8) over damper tube (3). Insert
damper tube into slider tube.

Insert spring (5) into slider tube with the tapered end down.
Push damper tube through opening at bottom of slider
tube using spring. Place sleeve (15) over end of damper
tube.

All except XL 1200X:

Install spring washer (21) and spring

collar (20) into slider tube.

Install slider tube assembly into slider. Install screw (18)
with washer (17) at bottom of slider. Move slider tube
through its full range of travel within slider several times
to verify proper component alignment. Then, applying
downward force on spring, final tighten screw to 132-216

in-lbs

(14.9-24.4 Nm).

NOTES

•

See

Figure 2-141

. Coat the lips (3) of the oil with HARLEY-

DAVIDSON SEAL GREASE.

•

Apply HARLEY-DAVIDSON SEAL GREASE to the mating
surfaces of the dust cover and the oil seal.

See

Figure 2-140

. Place upper bushing (1), spacer (2)

(concave side down) and oil seal (14) (lettering side up)
over slider tube. Place FORK SEAL AND BUSHING
INSTALLATION TOOL (Part No. HD-36583) over slider
tube. Install bushing, spacer and seal into slider bore by
tapping components downward with the installation tool.

Install internal circle clip (13) into groove in top of slider
bore.

Install dust seal (12) at top of slider.

10.

All except XL 883N:

Install cover (11).

11.

XL 883N:

See

Figure 2-144

. Slide a fork gaiter (2) down

each slider tube. Peel back the lower lip (3) and slip over
the end of fork slider (1). Fit the lower lip down over groove
in upper end of fork slider. Slide the upper end of fork
gaiter down as far as possible.

12.

All

except

883L

and

1200X/V/C/C

ANV/CP/CA/CB:

See

Figure 2-140

. Install the drain screw

and washer (19) into lower end of slider.

13. Fill the fork tube with fork oil. See

2.19 FRONT FORK: XL

MODELS, Fill with Fork Oil

sm07599

1. Air side
2. Oil side
3. Lips

Figure 2-141. Oil Seal

FILL WITH FORK OIL

TOOL NAME

PART NUMBER

OIL LEVEL GAUGE

HD-59000-B

Position fork tube assembly upright. Compress the
assembly fully.

Pour approximately 14 fl oz (414 mL) of TYPE "E"
HYDRAULIC FORK OIL into fork.

Pump the slider tube 8-10 times to expel air and compress
the assembly fully.

See

Figure 2-142

. Use the OIL LEVEL GAUGE (Part

No. HD-59000-B) to set the fork oil level.

Adjust the length of the draw off tube to specification
(1). Refer to

Table 2-21

Lock the tube (2) to the collar (3) with the thumb lock
(4).

Fit the collar to the fork tube.

Draw off the excess oil.

Install spring and other components.

NOTE

Apply HARLEY-DAVIDSON SEAL GREASE to the O-ring.

Install slider tube cap with O-ring. Screw tube cap all the
way into slider tube. Finger-tighten only.

HOME

2013 Sportster Service: Chassis 2-101

Harley Davidson 2013 Sportster Models. Service Manual - page 2