Harley Davidson 2013 Sportster Models. Service Manual - page 6

sm04938

1. Air box assembly
2. Air filter cover
3. Active intake connector [178] (if equipped)
4. Wiring harness
5. Recess

Figure 1-15. Installing Air Filter Cover

CLEANING FILTER ELEMENT

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

NOTE

Do not tap the filter on a hard surface.

Wash the filter in warm soapy water.

To remove soot, soak the filter in warm soapy water for
30 minutes.

NOTE

The filter is clean if light is visible through filter.

Hold the filter up to light.

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)

Dry the filter with low-pressure compressed air from the
inside.

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1-22 2013 Sportster Service: Maintenance

1.8

TIRES AND WHEELS

AIR PRESSURE

Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)

Always maintain proper tire pressure as specified in

Table 1-7

Do not load tires beyond GAWR specified in

Table 2-4

Underinflated, over-inflated or overloaded tires can fail.

Check tire pressure when the tires are cold. Refer to

Table 1-7

NOTE

Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.

Table 1-7. Air Pressure (cold): 2013 Sportster Models

kPa

psi

WHEEL

MODEL

248

Front

XL 883L

290

Rear

207

Front

XL 883N

276

Rear

207

Front

XL 883R

276

Rear

248

Front

XL 1200C/C ANV

276

Rear

248

Front

XL 1200CP

276

Rear

248

Front

XL 1200CA

276

Rear

248

Front

XL 1200CB

276

Rear

207

Front

XL 1200V

276

Rear

248

Front

XL 1200X

276

Rear

248

Front

XR 1200X

290

Rear

TIRE REPLACEMENT

Tread Wear

Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)

Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in (0.8 mm) tread depth
remains, the tire can:

•

Be more easily damaged leading to tire failure.

•

Provide reduced traction.

•

Adversely affect stability and handling.

Replace the tires with

new

tires before the tread wear bars

appear:

•

See

Figure 1-16

Figure 1-17

. Indicators (1) on the tire

sidewalls point to tread wear bars (2) in the tread.

•

Tread wear bars appear in the tread pattern when 1/32 in
(0.8 mm) or less of tread remains.

sm07185d

1. Indicator
2. Tread wear bar

Figure 1-16. Tread Pattern: Michelin Tires

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2013 Sportster Service: Maintenance 1-23

sm07439a

1. Indicator
2. Tread wear bar

Figure 1-17. Tread Pattern: Dunlop Tires

Tire Damage

Replace tires with

new

tires when:

•

Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.

•

A bump, bulge or split is found anywhere on the tire.

•

A puncture, cut or other damage cannot be repaired.

SPECIFIED TIRES

Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)

Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)

•

Store

new

tires on a horizontal tire rack. Do not stack tires

in a vertical stack.

•

Mount only Harley-Davidson specified tires. Refer to

Table 1-8

Table 1-8. Specified Tires: 2013 Sportster Models

SPECIFIED TIRE

WHEEL

MODEL

Michelin Scorcher "11F" 120/70ZR18

XL 883L

Michelin Scorcher "11" 150/60ZR17

Michelin Scorcher "31" 100/90B19

XL 883N/R

Michelin Scorcher "31" 150/80B16

Michelin Scorcher "31" 130/90B16

XL 1200C/X
XL 1200C
ANV
XL 1200CP
XL 1200CA
XL 1200CB

Michelin Scorcher "31" 150/80B16

Dunlop D402F MH90 21 M/C 54H WW

XL 1200V

Dunlop D401 150/80B16 M/C 71H
WWW

Michelin Scorcher "11F" 120/70ZR18

XR 1200X

Michelin Scorcher "11" 180/55ZR17

WHEEL BEARINGS

NOTE

Replace bearings in sets only. See

2.5 WHEELS, Sealed Wheel

Bearings

Replace when bearings exceed end play service wear
limit of 0.002 in (0.051 mm).

Inspect any time the wheels are removed.

Inspect the play of the wheel bearings by finger while
they are in the wheel.

Rotate the inner bearing race. Listen for abnormal
noise.

Verify smooth bearing rotation.

Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings.

WHEEL SPOKES

TOOL NAME

PART NUMBER

SPOKE TORQUE WRENCH

HD-48985

SPOKE NIPPLE WRENCH

HD-94681-80

TORQUE VALUE

FASTENER

6.2 Nm

in-lbs

Spoke nipple

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

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1-24 2013 Sportster Service: Maintenance

Do not over tighten spoke nipples. Protruding spoke
nipples can damage rim seal, resulting in rapid tire defla-
tion, which could cause death or serious injury. (00611b)

When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)

Identify Wheel Spoke Groups

NOTE

Spokes are grouped in sets of four.

Raise wheel with a suitable lifting device.

See

Figure 1-18

. Starting at the valve stem, identify the

first group of four spokes (1-4).

Using a different color for each spoke in the group, draw
an alignment mark across the spoke nipple and onto the
rim.

Continue around the wheel marking the rest of the spokes
the same as they were marked in the previous way.

Wheel Spoke Adjustment

NOTES

•

Do not tighten spoke more than 1/4 turn past alignment
mark. If more tension is needed, label spoke and check
after completing rest of wheel.

•

Do not use the spoke torque wrench to loosen spokes.
Use SPOKE NIPPLE WRENCH (Part No. HD-94681-80)
to loosen spokes.

See

Figure 1-18

. Starting with the first group of spokes,

loosen spoke (1) using SPOKE NIPPLE WRENCH (Part
No. HD-94681-80) 1/4 turn.

Using SPOKE TORQUE WRENCH (Part No. HD-48985)
tighten spoke (1) to the value listed in

Table 1-9

While tightening, if the torque wrench clicks before
the alignment marks align, continue to turn the spoke
nipple until the marks align.

If the alignment marks align and the torque specifica-
tion has not been reached, continue to tighten the
spoke nipple until the correct torque is achieved, but
do not turn spoke nipple more then 1/4 turn past
alignment mark.

Repeat previous two steps for spoke (4) in the same group.

Continue around the wheel checking spokes 1 and 4 until
all groups are done.

Repeat procedure for spokes (2, 3) in each group.

NOTE

When checking any spokes that were labeled, make sure to
use the original alignment mark.

Check spokes, if any, that were labeled as not reaching
the proper torque value after tightening 1/4 turn past
alignment mark.

Loosen spoke 1/4 turn past original alignment mark
using SPOKE NIPPLE WRENCH (Part No. HD-94681-
80).

While tightening, if the torque wrench clicks before
the alignment marks align, continue to turn the spoke
nipple until the marks align.

True the wheel. See

2.7 CHECKING AND TRUING

WHEELS

Table 1-9. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

in-lbs

(6.2 Nm)

All

sm06507

Figure 1-18. Tightening Laced Wheels (typical)

HOME

2013 Sportster Service: Maintenance 1-25

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

FUEL

SYSTEM

1.9

PRIMARY CHAIN

FREE PLAY ADJUSTMENT

TORQUE VALUE

FASTENER

27.1-33.9 Nm

20-25 ft-lbs

Primary chain adjuster locknut

10.2-13.6 Nm

90-120

in-lbs

Primary chain inspection cover

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

See

Figure 1-19

. Remove the primary chain inspection

cover (1).

NOTE

Rotate the engine to measure free play at several chain posi-
tions.

See

Figure 1-20

. Through the inspection opening, measure

chain free play at the tightest position.

NOTE

Factory Setting: The factory sets initial cold engine free play
to 1/4-3/8 in (6.35-9.53 mm). With the engine cold, measure
free play on a primary chain that has never been adjusted:

•

Less than 1/4 in (6.35 mm): Adjust to specification.

•

Between 1/4 in (6.35 mm) and 3/8 in (9.53 mm): Do NOT
adjust.

Do not adjust the primary chain tighter than specified.
Running chain too tight will result in excessive wear.
(00202a)

If the measurement is not in specification, adjust the
primary chain. Refer to

Table 1-10

See

Figure 1-19

. Loosen the locknut (2).

With a hex key, turn the adjuster screw (3) clockwise
to reduce free play or counterclockwise to increase
free play.

When free play is within specification, hold the
adjuster screw with a hex key and tighten the locknut
to 20-25 ft-lbs (27.1-33.9 Nm).

If the primary chain cannot be adjusted to specification,
replace the chain. See

5.4 PRIMARY DRIVE AND

CLUTCH: XL MODELS

5.5 PRIMARY DRIVE AND

CLUTCH: XR 1200X

Install a

new

gasket and the primary chain inspection

cover. Tighten to 90-120

in-lbs

(10.2-13.6 Nm).

Install main fuse.

sm06896

1. Inspection cover
2. Locknut
3. Adjuster screw

Figure 1-19. Primary Chain Inspection Cover and Adjuster

om00206c

Figure 1-20. Primary Chain Free Play

Table 1-10. Primary Chain Free Play Specifications

ENGINE

9.5-12.7

3/8-1/2

Cold

6.3-9.5

1/4-3/8

Hot

HOME

1-26 2013 Sportster Service: Maintenance

1.10

TRANSMISSION LUBRICANT

TRANSMISSION LUBRICATION

TORQUE VALUE

FASTENER

10.3-13.6 Nm

90-120

in-lbs

Clutch inspection cover
screws

19.0-40.7 Nm

14-30 ft-lbs

Primary chaincase drain plug

10.3-13.6 Nm

90-120

in-lbs

Clutch inspection cover
screws

Check Lubricant Level

Ride motorcycle until engine is warmed up to normal
operating temperature.

NOTE

Support motorcycle upright to equalize lubricant level in the
transmission compartments.

Position motorcycle upright.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove foot controls:

XL Models with Mid-mount Controls:

Remove left

side rider footrest and mounting bracket assembly.
See

2.40 RIDER FOOT CONTROLS: XL MID-MOUNT

CONTROLS

XR 1200X:

Remove left side rider footrest, mounting

bracket assembly, and shift linkage. See

2.42 RIDER

FOOT CONTROLS: XR 1200X

See

Figure 1-21

. Remove screws with washers and

remove clutch inspection cover (1).

See

Figure 1-22

. Verify that lubricant level is even with

bottom of clutch diaphragm spring (1).

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incomplete
disengagement, clutch drag and/or difficulty in finding
neutral at engine idle. (00199b)

If the level is low, add FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT through clutch
inspection cover opening. Verify that lubricant level is even
with bottom of clutch diaphragm spring.

Install the clutch inspection cover:

Install a

new

quad ring. Verify that the quad ring is

fully seated in groove of primary cover.

See

Figure 1-23

. Install cover and tighten screws in

sequence to 90-120

in-lbs

(10.3-13.6 Nm).

Install left side rider footrest:

XL Models with Mid-mount Controls:

Install left

side rider footrest and mounting bracket assembly.
See

2.40 RIDER FOOT CONTROLS: XL MID-MOUNT

CONTROLS

XR 1200X:

Install left side rider footrest, mounting

bracket assembly, and shift linkage. See

2.42 RIDER

FOOT CONTROLS: XR 1200X

10. Install main fuse.

11. Run engine. Check for leaks.

om00908

1. Clutch inspection cover
2. Drain plug
3. Primary chain inspection cover

Figure 1-21. Primary Cover: XL Model

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2013 Sportster Service: Maintenance 1-27

om00397

1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Quad ring
4. Primary cover
5. Chaincase lubricant level

Figure 1-22. Chaincase Lubricant Level

Change Lubricant

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

Ride motorcycle until engine is warmed up to normal
operating temperature.

Turn the engine off and position motorcycle on jiffy stand.
This will allow the chaincase lubricant to drain out of
transmission.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

See

Figure 1-21

. Position a suitable container under

transmission drain plug (2).

Remove drain plug. Drain lubricant.

Position the motorcycle straight up and level. This allows
additional fluid to be drained from clutch compartment.

NOTE

Dispose of lubricant in accordance with local regulations.

Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)

Clean magnetic drain plug. Replace O-ring if damaged.

Apply LOCTITE 565 THREAD SEALANT and install drain
plug. Tighten to 14-30 ft-lbs (19.0-40.7 Nm).

Remove the clutch inspection cover.

10. See

Figure 1-22

. Add 1.00 qt (0.95 L) of FORMULA+

TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT through clutch inspection cover opening. Verify
that lubricant level is even with bottom of clutch diaphragm
spring (1).

11. Install the clutch inspection cover:

Install a

new

quad ring. Verify that the quad ring is

fully seated in groove of the primary cover.

See

Figure 1-23

. Install cover and tighten screws in

sequence to 90-120

in-lbs

(10.3-13.6 Nm).

12. Install main fuse.

13. Run engine. Check for lubricant leaks.

sm07590

Figure 1-23. Clutch Inspection Cover Torque Sequence

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1-28 2013 Sportster Service: Maintenance

1.11

CLUTCH

ADJUSTMENT

TORQUE VALUE

FASTENER

10.3-13.6 Nm

90-120

in-lbs

Clutch inspection cover
screws

13.6 Nm

120

in-lbs

Clutch cable adjuster jamnut

Release the Clutch Cable Tension

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

XL Models:

See

Figure 1-24

. Remove cable adjuster from

the frame retaining clips.

See

Figure 1-25

. Pull the boot (1) away from the cable

adjuster (2).

Loosen the jamnut (3).

Turn the adjuster to loosen the clutch cable at the hand
lever.

sm01436a

Figure 1-24. Clutch Cable Adjuster Location: XL Models

sm01437a

1. Rubber boot
2. Cable adjuster
3. Jamnut
4. Cable end

Figure 1-25. Clutch Cable Adjuster

Clutch Adjustment

Access the clutch inspection cover:

XL Models with Mid-mount Controls:

Remove the

clutch side rider footrest and mounting bracket
assembly. See

2.40 RIDER FOOT CONTROLS: XL

MID-MOUNT CONTROLS

XR 1200X:

Remove the clutch side rider footrest and

shifter mounting bracket and a shift linkage pivot bolt.
See

2.42 RIDER FOOT CONTROLS: XR 1200X

Remove the clutch inspection cover. Discard the quad
ring.

See

Figure 1-26

. Remove the hex lockplate with the spring

(1) from the clutch adjusting screw (2).

Turn the adjusting screw counterclockwise until resistance
is felt and then turn the adjusting screw clockwise 1/4 turn.

Install the hex lockplate with the spring and turn the
adjusting screw clockwise to fit the lockplate onto the flats
of the adjusting screw.

Install the clutch inspection cover.

Install a

new

quad ring in the primary cover.

Install the inspection cover.

Install the screws and tighten in a cross pattern to 90-
120

in-lbs

(10.3-13.6 Nm).

Install the foot controls:

XL Models with Mid-mount Controls:

Install the

footrest and mounting bracket. See

2.40 RIDER

FOOT CONTROLS: XL MID-MOUNT CONTROLS

XR 1200X:

Install the rider footrest and shifter

mounting bracket and shift linkage. See

2.42 RIDER

FOOT CONTROLS: XR 1200X

HOME

2013 Sportster Service: Maintenance 1-29

sm01129a

1. Voltage regulator
2. Mounting screw (2)

Figure 6-91. Voltage Regulator Location

INSTALLATION: XL MODELS

TORQUE VALUE

FASTENER

4.1-6.8 Nm

36-60

in-lbs

Voltage regulator mounting
screw

Position voltage regulator close to mounting bracket. Orient
regulator so cooling fins face forward and wiring harnesses
exit regulator body toward right side of vehicle.

Route stator harness down along between right frame
downtube and body of voltage regulator. Route stator
harness connector [47A] toward right side of vehicle.

Mount voltage regulator on mounting bracket between
frame downtubes and secure with mounting screws at two
locations. Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

Plug stator connector [47A] into socket connector [47B].
Fold external locking latch over and lock in place.

Plug voltage regulator DC output connector [77A] into
socket [77B]. Fold external latch over and lock in place.

Install main fuse.

Test charging system. See the electrical diagnostic
manual.

REMOVAL: XR 1200X

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

NOTE

Never pull on wiring when unplugging voltage connector.

See

Figure 6-92

. Unplug stator connector (4). Carefully

pull barbed cable strap (3) from frame.

See

Figure 6-93

. Cut cable strap (1). Lift external latch on

connector and separate connector halves.

See

Figure 6-94

. Remove screws (1) from locations at top

and bottom of voltage regulator (2). Remove regulator
from vehicle, carefully threading harnesses through
opening in regulator mounting bracket.

sm05563

1. Oil pressure switch
2. J-clip
3. Barbed cable strap
4. Stator connector [47]

Figure 6-92. Oil Pressure Switch: XR 1200X

sm05585

1. Cable strap
2. DC output conector
3. Oil pressure switch, neutral switch harness
4. Oil filter

Figure 6-93. DC Output Connector: XR 1200X

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2013 Sportster Service: Electrical 6-61

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