Harley Davidson 2013 Sportster Models. Service Manual

sm01421

1. Front brake master cylinder assembly
2. Diaphragm
3. Diaphragm plate
4. Reservoir cover
5. Captive screw (2)

Figure 1-42. Front Brake Master Cylinder Cover Assembly

(typical)

NOTES

•

See

Figure 1-43

. Verify that the pad spring is installed

before installing the new pads.

•

Front and rear brake caliper pads are not interchangeable.

sm01428

Figure 1-43. Front Caliper Pad Spring

See

Figure 1-44

. Remove pad pin plug (3).

See

Figure 1-45

. Loosen, but do not remove, brake pad

pin.

NOTE

Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.

Once the pistons have been fully retracted into their bores,
pull pad pin part way until inside pad drops free. Note the
pad's original orientation for replacement purposes.

sm01429

1. Front brake caliper
2. Caliper mounting bracket
3. Pad pin plug
4. Caliper mounting pins

Figure 1-44. Front Caliper Assembly

sm01430

Figure 1-45. Brake Pad Pin (plug removed)

See

Figure 1-46

. Install

new

inside brake pad (1) using

same orientation as pad previously removed. Align
mounting tabs.

While holding

new

inside pad in place, pull pad pin out

and remove outside brake pad. Note the pad's original
orientation for replacement purposes.

10. Install

new

outside brake pad using the same orientation

as pad previously removed. Align mounting tabs.

11. Temporarily insert a 1/8 drill bit in caliper pad pin hole to

hold both pads in place.

12. Inspect pad pin for grooving and wear. Measure pad pin

diameter in an unworn area, and then in the area of any

HOME

1-42 2013 Sportster Service: Maintenance

grooving or wear. If wear exceeds 0.011 in (0.28 mm),
replace pin.

sm01431

1. Brake pad
2. Front mounting tab
3. Pad pin hole
4. Front caliper mounting bracket
5. Slot

Figure 1-46. Front Brake Pads

13. Press brake pads firmly up against pad spring. Remove

drill bit. Install pad pin. Tighten to 131-173

in-lbs

(14.8-

19.6 Nm).

NOTE

If pad pin does not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Pad spring orientation must match

Figure 1-43

•

See

Figure 1-46

. Fully seat mounting tabs (2) in slot (5).

•

Push pads against pad spring before installing pad pin.

14. See

Figure 1-44

. Install pad pin plug (3). Tighten to 18-25

in-lbs

(2.0-2.9 Nm).

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

15. Pump brake lever to move pistons out until they contact

outside brake pad. Verify piston location against pad.

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTE

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.

16. See

Figure 1-47

. Check brake fluid level in master cylinder.

Add enough DOT 4 BRAKE FLUID to reservoir to bring
fluid level even with ridge (1) cast into inside of reservoir,
about 1/4 in (6.35 mm) below top edge.

sm01422

1. Cast-in ridge
2. Sight glass

Figure 1-47. Filling Front Master Cylinder Reservoir

(typical)

17. See

Figure 1-42

. Install diaphragm (2), diaphragm plate

(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17

in-lbs

(1.0-2.0 Nm).

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)

HOME

2013 Sportster Service: Maintenance 1-43

18. Test brake system.

Turn ignition switch ON. Pump brake lever to verify
operation of the stop lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

2.17 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.

BRAKE PAD REPLACEMENT: REAR

TORQUE VALUE

FASTENER

14.8-19.6 Nm

131-173

in-lbs

Brake pad pin

2.0-2.9 Nm

18-25

in-lbs

Brake pad pin plug

NOTES

•

See

Figure 1-50

. Do not remove or loosen the caliper

mounting pins (4). Removing caliper from mounting bracket
increases the risk of contaminants falling into caliper boots
and bushings. These contaminants could damage caliper
during vehicle operation.

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Position vehicle on a flat level surface.

NOTE

See

Figure 1-48

. As the piston is pushed back into the caliper,

fluid level may rise higher than the upper fluid level (3) in the
reservoir (1). You may have to remove fluid to allow for this.

See

Figure 1-48

. Remove rear master cylinder reservoir

cap (2).

Place a suitable container under the rear master cylinder
to catch any fluid that may overflow.

sm01425

1. Rear brake master cylinder reservoir
2. Reservoir cap
3. Upper fluid level
4. Lower fluid level
5. Reservoir cover

Figure 1-48. Rear Brake Master Cylinder Reservoir: XL

Models

Press against the side of the brake caliper body to push
the outside brake pad (pad closest to caliper piston) back.
This pushes the caliper piston back into its bore.

NOTES

•

See

Figure 1-49

. Verify that the pad spring is installed

before installing new pads.

•

Front and rear brake pads are not interchangeable.

HOME

1-44 2013 Sportster Service: Maintenance

sm01432

Figure 1-49. Rear Caliper Pad Spring

See

Figure 1-50

. Remove pad pin plug (3).

See

Figure 1-51

. Loosen, but do not remove, brake pad

pin.

NOTE

Do not completely remove brake pad pin from caliper during
the next step. Completely removing pad pin at this time may
cause difficulty during assembly.

Once the piston has been fully retracted into its bore, pull
pad pin part way until inside pad drops free. Note the pad's
original orientation for replacement purposes.

sm03590a

1. Rear brake caliper
2. Caliper mounting bracket
3. Pad pin plug
4. Caliper mounting pins

Figure 1-50. Rear Caliper Assembly

sm01434

Figure 1-51. Brake Pad Pin (plug removed)

See

Figure 1-52

. Install

new

inside brake pad (2) using

same orientation as pad previously removed. Align
mounting tabs.

While holding

new

inside pad in place, pull pad pin out

and remove outside brake pad (1). Note the pad's original
orientation for replacement purposes.

10. Install

new

outside brake pad using the same orientation

as pad previously removed. Align mounting tabs.

11. Temporarily insert a 1/8-in (3.175 mm) drill bit in caliper

pad pin hole to hold pads in place.

12. Inspect pad pin for grooving and wear. Measure pad pin

diameter in an unworn area, and then in the area of any
grooving or wear. If wear exceeds 0.011 in (0.28 mm),
replace pin.

13. Press brake pads firmly up against pad spring. Remove

drill bit. Install pad pin. Tighten to 131-173

in-lbs

(14.8-

19.6 Nm).

HOME

2013 Sportster Service: Maintenance 1-45

NOTE

If pad pin does not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Pad spring orientation must match

Figure 1-49

•

See

Figure 1-52

. Pad front mounting tabs (3) must be fully

seated in mounting bracket slot (6).

•

Before the pad pin is installed, push pads up against the
pad spring.

14. See

Figure 1-50

. Install pad pin plug (3). Tighten to 18-25

in-lbs

(2.0-2.9 Nm).

sm01435a

1. Outside brake pad
2. Inside brake pad
3. Front mounting tab
4. Pad pin hole
5. Rear caliper mounting bracket
6. Slot

Figure 1-52. Rear Brake Pads

15. Pump brake pedal to move piston out until it contacts

outside brake pad. Verify piston location against pad.

NOTES

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Fill the rear brake master cylinder reservoir must be in a
level position.

•

See

Figure 1-48

. Reservoir cover (5) may be removed

from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.

16. See

Figure 1-48

. If desired, remove rear brake master

cylinder reservoir cover (5) by grasping cover and gently
pulling it straight away from reservoir (1).

17. Check brake fluid level in master cylinder reservoir. If

necessary, add DOT 4 BRAKE FLUID to reservoir until
fluid reaches upper fluid level (3).

18. Replace master cylinder reservoir cap (2). Replace

reservoir cover (5), if removed.

19. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the stop lamp.

Test ride motorcycle at low speed. If the brakes feel
spongy, bleed the system. See

2.17 BLEEDING

BRAKES

NOTE

Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.

HOME

1-46 2013 Sportster Service: Maintenance

1.17

BRAKE PADS AND DISCS: XR 1200X

INSPECTION

Brake Pads

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

See

Figure 1-53

. Replace brake pads if thickness of brake pad

friction material (3) is worn to 0.040 in (1.02 mm) or less.
Always replace both pads in a caliper as a set. See

1.17 BRAKE PADS AND DISCS: XR 1200X, Brake Pad
Replacement: Front

1.17 BRAKE PADS AND DISCS: XR

1200X, Brake Pad Replacement: Rear

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage or leakage.

Brake Disc Thickness, Lateral Runout and
Warpage

See

Figure 1-54

. The minimum brake disc (4) thickness is

stamped on the side of the disc. Replace disc if worn past
minimum thickness or badly scored.

Maximum brake disc lateral runout and warpage is 0.008 in
(0.2 mm) when measured near the outside diameter.

•

To replace front brake disc(s), see

2.5 WHEELS, Front

Wheel

•

To replace rear brake disc, see

2.5 WHEELS, Rear Wheel

sm07225

1. Front, from below
2. Rear, from above
3. MIN thickness

Figure 1-53. Brake Pad MIN Thickness: XR 1200X

sm05127

1. Friction material thickness
2. Pad backing plate
3. Friction material
4. Brake disc

Figure 1-54. Brake Pad Inspection (front brake shown)

HOME

2013 Sportster Service: Maintenance 1-47

BRAKE PAD REPLACEMENT: FRONT

TORQUE VALUE

FASTENER

14.8-19.6 Nm

131-173

in-lbs

Brake pad pin

1.0-2.0 Nm

9-17

in-lbs

Brake master cylinder, front,
reservoir cover screws

Removal

NOTES

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

Turn handlebar to level the front master cylinder reservoir.

See

Figure 1-55

. Remove two screws (5), reservoir cover

(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).

NOTE

As the pistons are pushed back into the caliper, fluid level may
rise higher than fluid level mark at about 1/4 in (6.35 mm) below
top of reservoir. Remove fluid as necessary to prevent overflow.

Wrap a shop towel around the master cylinder reservoir
to contain any brake fluid spills.

Pry between the brake pads and brake disc to force all
caliper pistons back into their bores. Do not to scratch the
rotor or cause warpage.

sm01421

1. Front brake master cylinder assembly
2. Diaphragm
3. Diaphragm plate
4. Reservoir cover
5. Captive screw (2)

Figure 1-55. Front Brake Master Cylinder Cover Assembly

(typical)

See

Figure 1-56

. Remove pad pins (1).

Remove pad spring (2) and brake pads through opening
in caliper assembly.

NOTE

The pad pins are manufactured with a relief near the center of
their length, where the pad spring touches. Do not use this
area as a measurement point to determine pad pin wear.

Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area and in the area of any grooving
or wear. If wear exceeds 0.011 in (0.28 mm), replace pin.

Inspect pad spring for wear or cracks. Replace if neces-
sary.

HOME

1-48 2013 Sportster Service: Maintenance

sm05128b

1. Pad pins
2. Pad spring

Figure 1-56. Front Caliper Assembly: XR 1200X

Installation

NOTE

See

Figure 1-57

. When replacing front brake pads, make sure

pad spring is installed with the arrow and word UP (2) pointing
up and captured by both pad pins (3).

See

Figure 1-56

. Install

new

outer brake pad and pad

spring. Make sure friction material faces brake disc.

NOTE

If pad pin does not fit, check the following:

•

You are using the correct set of pads.

•

Pad spring orientation must match

Figure 1-57

•

Push pads tight up against pad spring before pad pins are
installed.

While holding

new

outer pad in place, insert pad pins

through holes in tabs of pad and into pad spring.

Install

new

inner brake pad, making sure friction material

faces brake disc.

Push pad pins through holes in tabs of inner pad and into
holes in caliper housing.

Tighten pad pins to 131-173

in-lbs

(14.8-19.6 Nm).

sm05101

1. Banjo bolt hole
2. Arrow and word "UP"
3. Pad pins (2)

Figure 1-57. Front Caliper Pad Spring Orientation

Pump brake lever to move pistons out until they contact
outside brake pad. Verify piston location against pad.

NOTE

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.

See

Figure 1-58

. Check brake fluid level in master cylinder.

Add enough DOT 4 BRAKE FLUID to reservoir to bring
fluid level even with ridge (1) cast into inside of reservoir,
about 1/4 in (6.35 mm) below top edge.

HOME

2013 Sportster Service: Maintenance 1-49

sm01422

1. Cast-in ridge
2. Sight glass

Figure 1-58. Filling Front Master Cylinder Reservoir

(typical)

See

Figure 1-55

. Install diaphragm (2), diaphragm plate

(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17

in-lbs

(1.0-2.0 Nm).

Test brake system.

Turn ignition switch ON. Pump brake lever to verify
operation of the stop lamp.

Test ride the motorcycle at low speed. If the brakes
feel spongy, bleed the system. See

2.17 BLEEDING

BRAKES

NOTE

Avoid making hard stops for the first 100 mi (160 km). This
allows the new pads to become conditioned to the brake discs.

BRAKE PAD REPLACEMENT: REAR

TORQUE VALUE

FASTENER

14.8-19.6 Nm

131-173

in-lbs

Brake pad pin

2.0-2.9 Nm

18-25

in-lbs

Brake pad pin plug

Removal

NOTES

•

Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and
bushings. These contaminants could damage caliper
during vehicle operation.

•

See

Figure 1-60

. It is not required or recommended to

remove or loosen the caliper mounting fasteners (2).

•

It is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to replace
pads.

•

If DOT 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Place motorcycle in an upright, level position.

Remove rear master cylinder reservoir cover.

Place a suitable container under the rear master cylinder
to catch any fluid that may overflow.

NOTE

The fluid level can rise above the upper fluid level in the
reservoir. Remove fluid as necessary.

Press against the outside of the brake caliper body to push
the caliper piston back into its bore, forcing fluid back to
the reservoir.

NOTE

See

Figure 1-59

. Verify that pad spring is installed before

installing new pads.

sm05122

Figure 1-59. Rear Caliper Pad Spring

NOTE

Left shock absorber is disconnected from rear fork for clarity
of photograph. Pad replacement does not require the shock
be disconnected.

See

Figure 1-60

. Remove pad pin plug (1).

Loosen, but do not remove, brake pad pin (metric).

Pull pad pin part way out until inner pad drops free.
Remove pad and note the pad's original orientation for
replacement purposes.

Continue to remove pad pin until outer pad drops free.

HOME

1-50 2013 Sportster Service: Maintenance

Inspect pad pin for grooving and wear.

10. Measure pad pin diameter in an unworn area and then in

the area of any grooving or wear. If wear exceeds 0.011
in (0.28 mm), replace pin.

sm05129a

1. Pad pin plug
2. Mounting fasteners

Figure 1-60. Rear Caliper Assembly: XR 1200X

Installation

NOTE

The caliper and mounting bracket are shown removed for clarity
of photograph. Removal is not required to replace brake pads.

See

Figure 1-61

. Install

new

outside brake pad using the

same orientation as pad previously removed. Make sure
front mounting tab (3) is seated in slot (6) in caliper
mounting bracket and pad friction material faces brake
disc.

Install pad pin into caliper and through outer pad.

Position inner pad and continue to install pad pin while
pressing brake pads firmly up against pad spring. Tighten
pad pin to 131-173

in-lbs

(14.8-19.6 Nm).

NOTE

If pad pin does not fit, check the following:

•

The part number of the pads.

•

See

Figure 1-59

. Check pad spring orientation.

•

See

Figure 1-61

. Pad front mounting tabs (3) must be fully

seated in mounting bracket slot (6).

•

Push the pads tight up against pad spring before pad pin
is installed.

Install pad pin plug. Tighten to 18-25

in-lbs

(2.0-2.9 Nm).

sm01435a

1. Outside brake pad
2. Inside brake pad
3. Front mounting tab
4. Pad pin hole
5. Rear caliper mounting bracket
6. Slot

Figure 1-61. Rear Brake Pads: XR 1200X

Pump brake pedal to move piston out until it contacts
outside brake pad. Verify piston location against pad.

NOTE

Position rear brake master cylinder reservoir level when filling
or checking fluid level

Check brake fluid level in master cylinder reservoir. If
necessary, add DOT 4 BRAKE FLUID to reservoir until
fluid reaches upper fluid level.

Replace reservoir cover.

HOME

2013 Sportster Service: Maintenance 1-51

1.18

SPARK PLUGS

REMOVAL

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

NOTE

Allow the engine to cool before servicing.

Disconnect spark plug cables.

Remove spark plugs.

INSPECTION

NOTE

Discard plugs with eroded electrodes, heavy deposits or a
cracked insulator.

See

Figure 1-62

. Compare plug deposits to

Table 1-16

sm00099a

Figure 1-62. Spark Plug Deposits

Table 1-16. Spark Plug Deposit Analysis

POSSIBLE CAUSE

DEPOSITS

PLUG*

Worn pistons
Worn piston rings
Worn valves
Worn valve guides
Worn valve seals
Weak battery
Faulty ignition system

Wet, black and shiny

Air-fuel mixture too rich

Dry, fluffy or sooty
and black

Air-fuel mixture too lean
Hot running engine
Valves not seating
Improper ignition timing

Light brown and
glassy**
May be accompanied
by cracks in the insu-
lator or by electrode
erosion.

Balanced combustion
Clean off deposits at regular
intervals.

White, gray or tan
and powdery

* See

Figure 1-62

** The glassy deposit on a spark plug may cause high-speed
misfiring.

CLEANING

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)

If the plugs require cleaning between tune-ups:

Clean electrodes and insulator with electrical contact
cleaner. Dry plug with compressed air.

Use a thin file to flatten electrodes.

NOTE

Electrodes with sharp edges require 25-40 percent less voltage
than ones with rounded edges.

Check condition of threads in cylinder head. Use a penet-
rating oil and clean out with a thread chaser. Verify that
plug threads are clean.

If necessary, replace with

new

spark plugs.

INSTALLATION

TORQUE VALUE

FASTENER

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

Verify proper gap before installing

new

or cleaned spark

plugs.

Select a wire-type feeler gauge within specification.
Refer to

Table 1-17

HOME

2013 Sportster Service: Maintenance 1-53

NOTE

The spark plug gap is within specification when there is a
slight drag on the gauge.

Pass the wire gauge between the center and the outer
electrodes.

If necessary use the proper tool to bend the outer
electrode to bring the gap to within specification.

Apply ANTI-SEIZE LUBRICANT to the spark plug threads.
Tighten to 12-18 ft-lbs (16.3-24.4 Nm).

See

Figure 1-63

. Connect spark plug cables. Verify cables

are connected to coil, spark plugs and anchor clips or
harness caddies.

sm07488

Figure 1-63. Spark Plug Cable Routing: All Models

Table 1-17. Spark Plug Gap

TYPE

MODEL

0.97-1.09

0.038-0.043

6R12

0.81-0.97

0.032-0.038

10R12X

SPARK PLUG CABLE INSPECTION

Inspect spark plug cables. Replace if necessary.

Check for cracks or loose terminals.

Check for loose fit on ignition coil and spark plugs.

Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

See

Figure 1-64

. Check spark plug cable resistance with

an ohmmeter. Replace cables not meeting resistance
specifications. Refer to

Table 1-18

Table 1-18. Spark Plug Cable Resistance

RESISTANCE (OHMS)

CABLE

1,750-4,836

Front

4,843-15,420

Rear

sm02659a

1. Ohmmeter positive lead
2. Ohmmeter negative lead
3. Spark plug cable
4. Ohmmeter

Figure 1-64. Testing Resistance

HOME

1-54 2013 Sportster Service: Maintenance

1.19

STEERING HEAD BEARINGS

FALL-AWAY

TORQUE VALUE

FASTENER

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch bolt

40.7-47.5 Nm

30-35 ft-lbs

Fork bracket pinch screw

Measurement

Raise the front wheel off the floor.

Remove the components that interfere with front fork
swing.

Disconnect the clutch cable.

Cover the front fender tip with a strip of masking tape.

Install a pointer mounted to a floor stand. With the front
wheel pointed straight ahead, position the pointer at the
center of the fender.

Tap the fender on one side until the front fork begins to
pivot (fall-away) without being tapped. Mark that point.
Repeat in the opposite direction.

Measure the distance between the two fall-away marks.

If fall-away is not within specification, adjust the fork stem
bolt. Refer to

Table 1-19

Table 1-19. Fall-Away Specifications

MAXIMUM

MINIMUM

MODEL

2.0

1.0

XL models

100

4.0

2.0

XR 1200X

Adjustment

See

Figure 1-65

. Loosen the two lower bracket pinch

screws (2) and the fork stem pinch screw (1).

Adjust fall-away:

If fall-away is more than the maximum, loosen the
fork stem bolt (3).

If fall-away is less than the minimum, tighten the fork
stem bolt.

Tighten the fork stem pinch screw to 30-35 ft-lbs (40.7-
47.5 Nm) and tighten the lower bracket pinch screws to
30-35 ft-lbs (40.7-47.5 Nm).

Verify fall-away.

LUBRICATION

See

Figure 1-65

. Disassemble the steering head assembly

and lubricate the tapered roller bearings with SPECIAL PUR-
POSE GREASE. See

2.21 FORK STEM AND BRACKET

ASSEMBLY

sm06644a

1. Fork stem pinch screw
2. Bracket pinch screws
3. Fork stem bolt

Figure 1-65. Steering Head Assembly (typical)

HOME

2013 Sportster Service: Maintenance 1-55

1.20

CRITICAL FASTENERS

INSPECTION

Checking Torques on Fasteners

Inspect critical fasteners at the scheduled service intervals.
Replace any damaged or missing fasteners.

Attempt to turn the fastener using a torque wrench set to
the minimum torque specification for that fastener. Refer
to

Table 1-20

If the fastener does not rotate, the fastener torque
has been maintained. No further attention is neces-
sary.

If the fastener rotates, remove it to determine if it has
a locking agent.

If it has a locking agent, clean all locking material from
the threaded hole. Replace the fastener with a

new

one or clean the original fastener threads and apply
the appropriate locking agent (see appropriate pro-
cedure).

Install fastener. Tighten to specification.

If the fastener does not have a locking agent, install
fastener. Tighten to specification.

Table 1-20. Critical Fasteners

TORQUE

FASTENER

SYSTEM

4.0-5.1 Nm

35-45

in-lbs

Switch housing screws, upper and lower

Hand controls

12.2-14.9 Nm

108-132

in-lbs

Clutch lever handlebar clamp screws

12.2-14.9 Nm

108-132

in-lbs

Master cylinder handlebar clamp screws

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link screws

Engine

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link frame bracket mounting
screws, upper front

74.6-88.2 Nm

55-65 ft-lbs

Stabilizer link engine bracket mounting
screws, upper front

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link frame bracket mounting
screws, lower front

129-142 Nm

95-105 ft-lbs

Isolator mounting bolt, front

81.4-95.0 Nm

60-70 ft-lbs

Fork pivot/engine mount bolts

33.9-47.5 Nm

25-35 ft-lbs

Isolator mounting bracket screws, front (left
side)

33.9-47.5 Nm

25-35 ft-lbs

Isolator mounting bracket screws, rear (left
side)

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolts

Brakes

21.7-32.6 Nm

16-24 ft-lbs

Brake disc mounting screws, front

40.7-61.1 Nm

30-45 ft-lbs

Brake disc mounting screws, rear

1.0-2.0 Nm

9-17

in-lbs

Reservoir cover screws, front

23.1-29.9 Nm

17-22 ft-lbs

Master cylinder mounting screws, rear: XL

8.1-10.9 Nm

72-96

in-lbs

Master cylinder mounting screws, rear: XR

23.1-29.9 Nm

17-22 ft-lbs

Master cylinder bracket-to-frame mounting
screws, rear: XL

61-67.8 Nm

45-50 ft-lbs

Master cylinder/footrest bracket-to-frame
mounting screws, rear: XR

38.0-51.6 Nm

28-38 ft-lbs

Brake caliper mounting bolts, front

81-88 Nm

60-65 ft-lbs

Front

Axle nuts

129-142 Nm

95-105 ft-lbs

Rear

HOME

1-56 2013 Sportster Service: Maintenance

Table 1-20. Critical Fasteners

TORQUE

FASTENER

SYSTEM

40.7-47.5 Nm

30-35 ft-lbs

Lower bracket pinch screws

Front fork/handlebar

40.7-47.5 Nm

30-35 ft-lbs

Fork upper bracket pinch screws

31.2-36.6 Nm, loosen,

23-27 ft-lbs, loosen,

Fork stem bolt

8.1-10.9 Nm

72-96

in-lbs

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch screw

28.5-36.6 Nm

21-27 ft-lbs

Axle pinch screw, front: XL

55.6-65.1 Nm

41-48 ft-lbs

Axle pinch screw, front: XR

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp mounting screw

40.7-54.3 Nm

30-40 ft-lbs

Riser mounting bolts

81.3 Nm, loosen 180

degrees, 108 Nm

60 ft-lbs, loosen 180 degrees,

80 ft-lbs

Sprocket mounting bolts, rear

Final drive

HOME

2013 Sportster Service: Maintenance 1-57

Harley Davidson 2013 Sportster Models. Service Manual - page 9