Content .. 8 9 10 11 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 10

1.21

ENGINE MOUNTS AND STABILIZER LINKS

INSPECTION

Check engine mounts and stabilizer links as follows:

See

Figure 1-66

. Check for cracks or tears in engine mount

isolator rubber (17, 18).

Check for lateral movement at each end of the three sta-
bilizer links (8). Any lateral movement indicates the need

to replace the stabilizer link. Rotational movement does
not indicate excess wear.

Check that all engine mount bolts and stabilizer link screws
are tight. See

2.25 STABILIZER LINKS

2.26 FRONT

ENGINE MOUNT/ISOLATOR

, or

2.27 REAR ENGINE

MOUNT/ISOLATOR

for torque specifications.

Check that the mounts are supporting the weight of the
motor.

sm03285

15.

Stabilizer link bracket (2)

Stabilizer link (3)

Screw (3)

16.

Screw (2)

Engine bracket

Front isolator mount

10.

17.

Rear isolator mount

Screw (3)

Front mount isolator (2)

18.

11.

Rear mount isolator (2)

Nut

Screw (11)

19.

12.

Washer (4)

Grounding strap

Bolt

13.

20.

Rear fork pivot shaft

Spacer

Rear fork pivot bolt (2)

14.

Rear pivot lockplate

Lockwasher (2)

Figure 1-66. Engine Mounting Assemblies: All Models (typical)

HOME

1-58 2013 Sportster Service: Maintenance

1.22

BATTERY MAINTENANCE

GENERAL

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

Keep battery clean and lightly coat terminals with petro-
leum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)

AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The

batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.

NOTE

For charging information, see

1.22 BATTERY MAINTENANCE,

Charging Battery

. For testing information, see the electrical

diagnostic manual.

sm03272

1. Warning label
2. Positive (+) terminal
3. Negative (-) terminal
4. Warranty/date code label

Figure 1-67. Battery

om00618

Keep flames away

Contents are corrosive

Wear safety glasses

Read instructions

Keep away from children

Contents are explosive

Figure 1-68. Battery Warning Label

HOME

2013 Sportster Service: Maintenance 1-59

Table 1-21. Antidotes for Battery Acid

TREATMENT

CONTACT

Flush with water.

External

Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Internal

Flush with water. Get immediate medical
attention.

Eyes

BATTERY DISCONNECTION AND REMOVAL

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Open left side cover.

NOTE

Models with sirens: Verify that fob is present and turn ignition
key to IGNITION before removing main fuse or disconnecting
battery.

See

Figure 1-69

. Using a swivel socket (2), remove nut

that secures the negative (-) battery cable (1) connector
to ground stud (4) on crankcase boss behind starter motor
assembly (3). Remove cable connector from stud.

See

Figure 1-70

. Pull end of negative (-) cable (2) forward

gently to free it from cable holder (1).

See

Figure 1-71

. Press main fuse holder (1) toward the

rear of the motorcycle until it pops off its mounting pin on
battery strap (4). Remove main fuse holder from battery
strap.

Press data link connector (6) toward the rear of the
motorcycle until it pops off its mounting pin on battery
strap. Remove the connector from battery strap.

Remove battery strap screw (5). Unhook battery strap
from battery tray mount on top of battery and remove strap.

Lift up protective rubber boot covering battery positive (+)
terminal (3). Remove screw from battery positive (+) ter-
minal and remove positive (+) battery cable.

Disconnect positive (+) battery cable from cable holder
(2).

Slide the battery (with attached negative cable) out the
left side until the negative battery cable is accessible.

10. Disconnect the negative battery cable at the battery (-)

terminal. Leave the cable on the vehicle.

11. Remove battery from battery tray. Note routing of negative

(-) battery cable around frame downtube.

12. If battery is to be stored out of the motorcycle, close left

side cover.

sm06658

1. Negative (-) battery cable
2. Swivel socket
3. Starter motor assembly
4. Ground stud

Figure 1-69. Negative (-) Battery Connection

sm06659

1. Cable holder
2. Negative battery cable

Figure 1-70. Negative (-) Battery Cable Holder

HOME

1-60 2013 Sportster Service: Maintenance

sm06657

1. Main fuse and holder
2. Positive (+) battery cable holder
3. Positive (+) battery terminal (under protective

rubber boot)

4. Battery strap
5. Screw
6. Data link connector

Figure 1-71. Main Fuse and Battery Location: All Models

CLEANING AND INSPECTION

NOTE

Battery top must be clean and dry. Dirt and electrolyte on top
of the battery causes battery to self-discharge.

Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water).

When the solution stops bubbling, rinse off the battery with
clean water.

Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

Inspect the battery screws, and cables for breakage, loose
connections and corrosion.

Check the battery terminals for melting or damage caused
by over-tightening.

Inspect the battery for discoloration, raised top or a warped
or distorted case. This might indicate that the battery has
been frozen, overheated or overcharged.

Inspect the battery case for cracks or leaks.

VOLTMETER TEST

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Voltmeter Test

The voltmeter test provides a general indicator of battery con-
dition. Check the voltage of the battery to verify that it is fully
charged.

If the open circuit (disconnected) voltage reading is below
12.6 V:

Charge the battery.

Check the voltage after the battery has set for at least
one hour.

If the voltage reading is 12.7 V or above:

Perform a battery diagnostic test. See the electrical
diagnostic manual for the load test procedure.

Refer to

Table 1-22

Table 1-22. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGE

VOLTAGE (OCV)

100%

12.7 V

75%

12.6 V

50%

12.3 V

25%

12.0 V

11.8 V

CHARGING BATTERY

Safety Precautions

An automatic, constant monitoring battery charger/tender with
a charging rate of 5 amps or less at less than 14.6 volts is
recommended. The use of constant current chargers (including
trickle chargers) to charge sealed AGM batteries is not
recommended.

Any overcharge will cause dry-out and premature battery
failure. Always review charger instructions before charging a
battery. In addition to the manufacturer's instructions, follow
these general safety precautions:

•

Always wear eye, face and hand protection.

•

Always charge batteries in a well-ventilated area.

•

Turn the charger off before connecting or disconnecting
the leads to the battery to avoid dangerous sparks.

•

Never try to charge a visibly damaged or frozen battery.

•

Connect the charger leads to the battery. Red positive
lead to the positive terminal. Black negative lead to the
negative terminal. If the battery is still in the vehicle, con-

HOME

2013 Sportster Service: Maintenance 1-61

nect the negative lead to the chassis ground. Verify that
the ignition and all electrical accessories are turned off.

•

Verify that charger leads to battery are not separated,
frayed or loose.

•

If the battery temperature exceeds 110 °F (43 °C) during
charging, discontinue charger and allow the battery to
cool.

Using a Battery Charger

Charge the battery if:

•

Vehicle lights appear dim.

•

Electric starter sounds weak.

•

Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

Check charge state with voltmeter test. If battery voltage
is less than 12.7 volts, see the next step.

NOTES

•

Most constant monitoring battery chargers are completely
automatic. They can be left connected to both AC power
and to the battery that is being charged. When leaving this
type of charger connected for extended periods of time,
periodically check the battery to see if it is unusually warm.
This is an indication that the battery may have a weak cell
or internal short. Read the manufacturer's instructions for
the charger.

•

Do not use battery chargers that produce excessively high
voltage designed for flooded batteries or excessively high
current designed for much larger batteries. Charging
should be limited to 5 amps maximum at no more than
14.6 volts.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

Connect red battery charger lead to the positive terminal
and black battery charger lead to the negative terminal of
the battery.

NOTE

If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.

Step away from the battery and turn on the charger.

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

After the battery is fully charged, turn the charger OFF.
Disconnect the black battery charger lead to the negative
terminal of the battery.

Disconnect the red battery charger lead to the positive
terminal of the battery.

Mark the charging date on the battery.

Perform a battery diagnostic test to determine the condition
of the battery. See the electrical diagnostic manual.

If charging a battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the electrical
diagnostic manual.

BATTERY INSTALLATION AND
CONNECTION

TORQUE VALUE

FASTENER

6.8-7.9 Nm

60-70

in-lbs

Battery negative terminal
screw

4.1-6.8 Nm

36-60

in-lbs

Battery strap screw

6.8-7.9 Nm

60-70

in-lbs

Battery positive terminal screw

6.2-8.5 Nm

55-75

in-lbs

Battery cable connector nut

Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

Open left side cover.

Apply a light coat of petroleum jelly or corrosion retardant
material to the negative (-) battery terminal.

Slide fully charged battery into battery tray.

Insert screw through negative battery cable and into neg-
ative battery terminal. Thread screw into terminal. Tighten
screw to 60-70

in-lbs

(6.8-7.9 Nm).

Verify that the negative (-) battery cable is disconnected
from the ground stud on crankcase.

Hook top of battery strap (4) to battery tray mount on top
of battery. Install strap screw (5). Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

HOME

1-62 2013 Sportster Service: Maintenance

Route main positive battery cable through holders on
electrical bracket.

Hook main fuse holder (1) to top pin on battery strap and
slide forward until it snaps into place.

Hook data link connector (6) to bottom pin on battery strap
and slide forward until it snaps into place.

10. See

Figure 1-70

. Press negative (-) battery cable (2) into

cable holder (1).

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)

11. See

Figure 1-71

. With negative battery cable disconnected,

insert positive terminal screw through main fuse cable
then main positive battery cable. Install screw into positive
battery terminal (3). Tighten to 60-70

in-lbs

(6.8-7.9 Nm).

12. Apply a light coat of petroleum jelly or corrosion retardant

material to the positive (+) battery terminal. Place pro-
tective rubber boot over terminal.

13. See

Figure 1-69

. Place negative (-) battery cable connector

onto ground stud (4) on crankcase boss behind starter
motor assembly (3). Thread nut onto stud.

14. See

Figure 1-72

Figure 1-73

. Press negative (-) battery

cable connector (1) against cable stop (2) on crankcase
and tighten nut (3) to 55-75

in-lbs

(6.2-8.5 Nm).

15. Close left side cover.

sm03277a

1. Negative battery cable connector
2. Cable stop
3. Nut

Figure 1-72. Attaching Negative (-) Battery Cable to Ground

Stud Crankcase: XL Models

sm05267a

1. Negative battery cable connector
2. Cable stop
3. Nut

Figure 1-73. Attaching Negative (-) Battery Cable to Ground

Stud Crankcase: XR 1200X

STORAGE

TOOL NAME

PART NUMBER

GLOBAL BATTERY CHARGER

99863-01A

If the motorcycle is stored with the security system armed,
connect

automatic,

constant

monitoring

battery

charger/tender to maintain battery charge. Refer to the Harley-
Davidson Parts and Accessories catalog.

If the motorcycle is stored with the battery installed, without a
GLOBAL BATTERY CHARGER, and with the security system

not

armed, remove main fuse.

If the motorcycle will not be operated for several weeks, such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See

Figure 1-74

. A battery that is removed from the vehicle is

affected by self-discharge. A battery that is stored in the vehicle
is affected by self-discharge and, more significantly, by parasitic
loads. A parasitic load is caused by things like diode leakage
or maintaining computer memory with the vehicle turned off.

Batteries self-discharge at a faster rate at higher ambient
temperatures. To reduce the self-discharge rate, store battery
in a cool, dry place.

Charge the battery every two weeks if stored in the vehicle.
Charge the battery once per month if stored out of the vehicle.

NOTE

Use the GLOBAL BATTERY CHARGER (Part No. 99863-01A)
to maintain battery charge for extended periods of time without
risk of overcharging or boiling.

HOME

2013 Sportster Service: Maintenance 1-63

50 %

75 %

100 %

om00036

1. Capacity
2. Months of non-use
3. Measured at 105 °F (40 °C)
4. Measured at 77 °F (25 °C)

Figure 1-74. Effective Rate of Temperature on Battery

Self-discharging Rate

HOME

1-64 2013 Sportster Service: Maintenance

1.23

EXHAUST SYSTEM

EXHAUST SYSTEM LEAK CHECK

Check entire exhaust system for loose or missing
fasteners, damaged pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

Check for loose or damaged heat shields. Repair or
replace as necessary.

Check for exhaust leaks:

Start engine.

Cover muffler end with a clean dry shop towel.

Listen for exhaust leakage.

Remove shop towel.

Correct any leaks detected. See

4.13 EXHAUST SYSTEM:

XL MODELS

4.14 EXHAUST SYSTEM: XR 1200X

HOME

2013 Sportster Service: Maintenance 1-65

1.24

WHEEL ALIGNMENT

TOOL NAME

PART NUMBER

AXLE ALIGNMENT PLUGS

HD-48856-A

TORQUE VALUE

FASTENER

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

Checking Wheel Alignment

Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)

NOTE

Some models may require muffler removal.

See

Figure 1-75

. Insert alignment plugs (1, 2) from the

AXLE ALIGNMENT PLUGS (Part No. HD-48856-A) into
right and left ends of rear axle. Turn handle until plug is
firmly held in the axle.

XL Models:

See

Figure 1-76

. Fabricate an alignment tool

using a piece of 1/8 in (3.175 mm) diameter aluminum
welding rod 21.5 in (546 mm) long:

Grind one end down to a blunt point.

Use pliers to bend rod at a 90 degree angle, 2.25 in
(57 mm) from the blunt point.

Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.

XR 1200X:

See

Figure 1-77

. Fabricate an alignment tool

using a piece of 1/8 in (3.175 mm) diameter aluminum
welding rod 22.375 in (568 mm) long:

Grind one end down to a blunt point.

Use pliers to bend rod as shown.

Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.

Gauge distance between rear fork pivot bolt and rear axle
alignment plug center:

See

Figure 1-78

. Insert blunt point of alignment tool

in rear fork pivot bolt dimple (2) on right side of rear
fork (3).

Slide rubber grommet along tool shaft until it aligns
with hole in center of alignment plug (5).

Without moving grommet, position alignment tool on
left side of rear fork.

Verify measurements match on both sides of axle. Adjust
if necessary.

sm07441a

1. RH alignment plug
2. LH alignment plug

Figure 1-75. Axle Alignment Plugs

sm05426

1. Blunt point
2. Rubber grommet
3. 2.25 in (57 mm)
4. 19.25 in (489 mm)

Figure 1-76. Wheel Alignment Tool: XL Models

HOME

1-66 2013 Sportster Service: Maintenance

sm05427

1. Blunt point
2. Rubber grommet
3. 5/8 in (16 mm)
4. 15-1/4 in (387 mm)
5. 6-1/2 in (165 mm)
6. 3-7/8 in (98 mm)

Figure 1-77. Wheel Alignment Tool: XR 1200X

sm01615a

1. Wheel alignment tool
2. Rear fork pivot bolt dimple
3. Rear fork
4. Rubber grommet
5. Axle alignment plug

Figure 1-78. Checking Wheel Alignment Using Wheel

Alignment Tool: XL Models

Adjusting Wheel Alignment

Remove and discard E-clip.

Loosen rear axle nut.

On side of rear fork that has longer distance from pivot
bolt to axle center, turn nut on axle adjuster counterclock-
wise to shorten distance. Adjust axle until left and right
side alignment measurements are equal.

NOTES

•

Keep axle adjuster mechanisms firmly seated (under ten-
sion) on each side of rear fork during wheel alignment
procedures above. Do so by applying moderate upward
force on lower span of drive belt. This tensions drive belt,
which holds rear axle forward against both adjuster
mechanisms.

•

Do not tighten rear axle nut or install new E-clip until after
checking drive belt tension.

Verify drive belt deflection after aligning rear wheel. Adjust
if required. See

1.12 DRIVE BELT AND SPROCKETS,

Drive Belt Deflection

NOTE

If rear axle has been moved, verify slack in rear brake line
between clamp and rear caliper. If necessary, reposition brake
line. See

1.12 DRIVE BELT AND SPROCKETS, Drive Belt

Deflection

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

Tighten axle nut to 95-105 ft-lbs (129-142 Nm) and install

new

E-clip.

Install muffler if removed.

HOME

2013 Sportster Service: Maintenance 1-67

1.25

SUSPENSION ADJUSTMENTS

FRONT FORK: XR 1200X

Adjust both forks equally. Improper fork adjustment can
lead to loss of control, which could result in death or ser-
ious injury. (00124c)

Compression and rebound adjusting valves may be dam-
aged if too much force is used at either end of the adjust-
ment range. (00237a)

Spring Preload

See

Figure 1-79

. With a hex key, turn the preload adjuster

counterclockwise until it stops. This is the minimum preload
setting.

Calculate the total load and turn the adjuster clockwise to
specification. Refer to

Table 1-23

Rebound Damping

See

Figure 1-80

. Turn the rebound damping adjuster (1)

clockwise H (hard) until it stops. This is the maximum
rebound setting.

Turn adjuster counterclockwise S (soft) to specification.
Refer to

Table 1-24

Compression Damping

See

Figure 1-80

. Turn the compression damping adjuster

(2) clockwise H (hard) until it stops. This is the maximum
compression setting.

Turn the adjuster counterclockwise S (soft) to specification.
Refer to

Table 1-24

om01386

Figure 1-79. Spring Preload Adjuster: XR 1200X

Table 1-23. Recommended Spring Preload: XR 1200X

TURNS**

FROM

MINIMUM

LOAD*

0-4

Less than 165 lb (75.0 kg)

4-6

165-195 lb (75.0-89.0 kg)

6-8

195-225 lb (89.0-102.0 kg)

8-10

225-255 lb (102.0-116.0 kg)

More than 10

255 lb (116.0 kg) to maximum added weight
allowed. Refer to

Table 2-4

*Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
**Turns are clockwise turns in from minimum.
•

To increase preload, turn the adjuster clockwise.

•

To decrease preload, turn the adjuster counterclockwise.

om01385

1. Rebound damping adjuster
2. Compression damping adjuster

Figure 1-80. Fork Rebound and Compression Damping

Adjusters: XR 1200X

Table 1-24. Recommended Fork Rebound and

Compression Damping: XR 1200X

TURNS FROM MAX**

DAMPING*

Rebound (REB)

Compression (COM)

*Turns are counterclockwise out from maximum.
•

To increase damping, turn adjuster clockwise (H).

•

To decrease damping, turn adjuster counterclockwise
(S).

HOME

1-68 2013 Sportster Service: Maintenance

SHOCK ABSORBER PRELOAD: ALL
MODELS

TOOL NAME

PART NUMBER

SHOCK ADJUSTMENT SPANNER

94448-82B

Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)

Do not turn the shock absorber adjustment collar clock-
wise beyond adjustment setting 5. Doing so may result in
equipment damage. (00166b)

NOTES

•

Five position shocks: See

Figure 1-83

. Do not turn the

preload cam past position five (5) to position one (1) or
from position one (1) to position five (5).

•

Three position shocks: Do not turn the preload cam past
position three to position one or from position one (1) to
position three.

XL Models:

See

Figure 1-81

. Using SHOCK ADJUSTMENT

SPANNER (Part No. 94448-82B), turn the adjustment cam to
specification.

•

Five position shocks:

Refer to

Table 1-25

•

Three position shocks:

Refer to

Table 1-26

XR 1200X:

See

Figure 1-82

. Use the spanner wrench with

extension handle from the tool kit to turn the adjustment cam
to specification. Refer to

Table 1-25

om00396a

Figure 1-81. Shock Absorber Preload Adjustment: XL

Models

om01381b

Figure 1-82. Shock Absorber Preload Adjustment: XR

1200X

pd00442

Figure 1-83. Shock Preload Cam Positions (typical)

XL 883L/N, XL1200X/V and certain XL1200CP models are
configured for solo operation. If you choose to add a passenger
and/or cargo to the vehicle, the ride quality may be comprom-
ised. See a Harley-Davidson dealer for two-up seats, passenger
pegs and suspension options.

Table 1-25. Recommended Shock Preload: Five Position

POSITION**

LOAD*

Less than 165 lb (75.0 kg)

165-195 lb (75.0-89.0 kg)

195-225 lb (89.0-102.0 kg)

225-255 lb (102.0-116.0 kg)

255 lb (116.0 kg) to maximum added
weight allowed. Refer to

Table 2-3

and

Table 2-4

* Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
** See

Figure 1-83

HOME

2013 Sportster Service: Maintenance 1-69

Table 1-26. Recommended Shock Preload: Three Position

POSITION

LOAD*

Less than 165 lb (75.0 kg)

165-225 lb (75.0-102.0 kg)

225 lb (102.0 kg) to maximum added
weight allowed. Refer to

Table 2-4

and

Table 2-3

* Add the weight of the rider, passenger, riding gear,
accessories, and cargo.

Table 1-27. Maximum Added Weight Allowed: Sportster

Models

MAX LOAD

MODEL

198.2

437

XL 883L

197.3

435

XL 883N

193.7

427

XL 883R

189.6

418

XL 1200C/C ANV/CP

193.7

427

XL 1200CA

193.7

427

XL 1200CB

196.4

433

XL 1200X

201.8

445

XL 1200V

193.7

427

XR 1200X

SHOCK ABSORBER REBOUND AND
COMPRESSION: XR 1200X

Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)

Compression and rebound adjusting valves may be dam-
aged if too much force is used at either end of the adjust-
ment range. (00237a)

Shock Absorber Rebound Damping
Adjustment

See

Figure 1-84

. Turn the rebound adjuster in the direction

of the embossed H (hard) until it stops. This is the max-
imum rebound damping setting.

Turn the rebound adjuster toward the embossed S (soft)
the recommended number of clicks. Refer to

Table 1-28

Shock Absorber Compression Damping
Adjustment

See

Figure 1-85

. Using fingers, turn the compression

adjuster clockwise H (hard) until it stops. This is the max-
imum compression damping setting.

Turn the compression adjuster counterclockwise (H to S)
(hard to soft) the recommended number of clicks. Refer
to

Table 1-28

om01382

Figure 1-84. Rebound Damping Adjuster: XR 1200X

sm06884

Figure 1-85. Compresson Damping Adjuster: XR 1200X

Table 1-28. Recommended Rear Shock Rebound and

Compression Damping: XR 1200X

CLICKS FROM MAX

(H to S)

DAMPING

Rebound (REB)

Compression (COMP)

SUSPENSION TUNING: XR 1200X

After the suspension has been set to the recommend settings
and the tires have been inflated to recommended pressures,
ride the motorcycle and adjust the suspension damping as
required. Refer to

Table 1-29

HOME

1-70 2013 Sportster Service: Maintenance

Table 1-29. Suspension Damping Adjustment Guidelines: XR 1200X

SUGGESTED REMEDY

MOTORCYCLE BEHAVIOR

Increase rebound damping.

Soft or unsettled feeling around corners or after bumps

Increase rebound damping.

Leaping feeling or topping after large bumps

Decrease rebound damping.

Harsh/sharp feedback over bumps

Decrease rebound damping.

Feels like motorcycle drops down over chatter bumps

Increase compression damping.

Excessive bottoming through potholes

Increase compression damping (forks).

Excessive dive when applying front brake

Decrease compression damping.

Hard feeling or inadequate absorption over bumps

Decrease compression damping.

Feels excessively stiff or busy around corners

HOME

2013 Sportster Service: Maintenance 1-71

1.26

HEADLAMP ALIGNMENT

The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)

NOTE

Adjust the headlamps of motorcycles with multiple beam
headlamps to converge into one pattern.

Check the tire pressure.

Adjust the rear shocks for the rider and intended load.

Fill fuel tank or add an equal amount of ballast.

NOTE

Choose a wall in minimum light.

See

Figure 1-86

. Park the motorcycle in a line (1) perpen-

dicular to the wall.

Position motorcycle so that front axle is 25 ft (7.6 m) from
wall.

Draw a vertical line (2) on the wall.

With the motorcycle loaded, point the front wheel straight
forward at wall. Measure the distance (4) from the floor to
the center of the high beam bulb.

Draw a horizontal line (5) through the vertical line on the
wall. Place line 2.1 in (53.3 mm) lower than the measured
bulb centerline.

NOTE

The headlamp is aligned when the light beam hot spot is
centered over the intersection of the lines.

Verify headlamp alignment. Adjust as necessary.

om00835c

1. Perpendicular line
2. Vertical line
3. 25 ft (7.6 m)
4. High beam bulb centerline
5. Horizontal line 2.1 in (53.3 mm) lower than bulb

centerline

Figure 1-86. Headlamp Alignment: Sportster Models

HEADLAMP: ADJUSTMENT

TORQUE VALUE

FASTENER

40.7-47.5 Nm

30-35 ft-lbs

Headlamp horizontal adjust-
ment: XL 1200X/C/C
ANV/CP/CA/CB/V

40.7-47.5 Nm

30-35 ft-lbs

Headlamp vertical adjustment:
XL 1200X/C/C
ANV/CP/CA/CB/V

14-27 Nm

120-240

in-lbs

Headlamp clamp nut: XL
883L/N/R, XR 1200X

Adjustment: XL 1200X/C/C ANV/CP/CA/CB/V

Set horizontal adjustment:

See

Figure 1-87

. Loosen the horizontal adjustment

screw (3).

Turn the headlamp right or left as necessary to direct
the light beam straight ahead.

Tighten the horizontal adjustment screw to 30-35 ft-
lbs (40.7-47.5 Nm).

Set vertical adjustment:

Loosen the locknut (1) for the vertical adjustment bolt.

Tilt headlamp up or down to properly aim it at the
horizontal line on the wall.

Tighten headlamp locknut to 30-35 ft-lbs (40.7-47.5
Nm).

HOME

1-72 2013 Sportster Service: Maintenance

sm06940

1. Locknut
2. Vertical adjustment bolt
3. Horizontal adjustment screw

Figure 1-87. Headlamp Adjustment: XL 1200X/C/C

ANV/CP/CA/CB/V

Adjustment: XL 883R/L/N, XR 1200X

See

Figure 1-88

. Remove snap plug (1) on top of head-

lamp bracket (2).

Loosen headlamp clamp nut (3).

Tilt headlamp up or down to properly aim it in relation to
the horizontal line and, at the same time, turn it right or
left to direct light beam straight ahead.

Tighten headlamp clamp nut to 120-240

in-lbs

(14-27 Nm)

after lamp is properly positioned.

Install snap plug in headlamp bracket.

om01439

1. Snap plug
2. Headlamp bracket
3. Clamp nut

Figure 1-88. Headlamp Adjustment: XL 883R/L/N, XR 1200X

(XR 1200X shown)

HOME

2013 Sportster Service: Maintenance 1-73

Content .. 8 9 10 11 ..