Harley Davidson 2013 Sportster Models. Service Manual

2.2

SPECIFICATIONS

TABLES

Chassis

Table 2-1. Dimensions: XL 883 Models

XL 883N

XL 883L

XL 883R

ITEM

1519

59.8

1506

59.3

1524

60.0

Wheel base

3.9

3.8

142

5.6

Road clearance

653

25.7

648

25.5

693

27.3

Seat height*

*With 180 lb (81.7 kg) rider on seat.

Table 2-2. Dimensions: XL 1200 Models and XR 1200X

XR 1200X

XL 1200V

XL 1200X

XL 1200CB

XL 1200CA

XL 1200C/C ANV

ITEM

1524

60.0

1524

60.0

1519

59.8

1520

59.8

1520

59.8

1520

59.8

Wheel base

150

5.9

120

4.7

3.9

110

4.3

110

4.3

110

4.3

Road clearance

742

29.2

676

26.6

660

26.0

676

26.6

676

26.6

676

26.6

Seat height*

*With 180 lb (81.7 kg) rider on seat.

Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can lead to component
failure and adversely affect stability, handling and perform-
ance, which could result in death or serious injury. (00016f)

•

GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider, pas-
senger and cargo that can be safely carried.

•

GAWR is the maximum amount of weight that can be
safely carried on each axle.

•

The GVWR and GAWR are shown on the information
plate, located on the frame down tube.

NOTES

•

The maximum additional weight allowed on the motorcycle
equals the Gross Vehicle Weight Rating (GVWR) minus
the running weight. For example, a motorcycle with GVWR
of 1200 lbs (544 kg) having a running weight of 800 lbs
(363 kg), would allow a maximum of an additional 400 lbs
(181 kg) combined weight of the rider, passenger, riding
gear, cargo and installed accessories.

•

For important information regarding tire data and tire
inflation, see

1.8 TIRES AND WHEELS

Table 2-3. Weights: XL 883 Models

XL 883N

XL 883R

XL 883L

ITEM

256.3

565

260.0

573

255.4

563

Running weight*

197.3

435

193.7

427

198.2

437

Maximum added weight
allowed**

453.6

1000

453.6

1000

453.6

1000

GVWR

152.0

335

152.0

335

154.0

339

GAWR front

301.6

665

301.6

665

300.0

661

GAWR rear

*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this weight.

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2013 Sportster Service: Chassis 2-9

Table 2-4. Weights: XL 1200 Models and XR 1200X

XR 1200X

XL 1200V

XL 1200X

XL 1200CB

XL 1200CA

XL 1200C/C ANV

ITEM

259.9

573

251.7

555

257.2

567

260.0

573

260.0

573

264.0

582

Running weight*

193.7

427

201.8

445

196.4

433

193.7

427

193.7

427

189.6

418

Maximum added
weight allowed**

453.6

1000

453.6

1000

453.6

1000

453.6

1000

453.6

1000

453.6

1000

GVWR

154.2

340

152.0

335

152.0

335

152.0

335

152.0

335

152.0

335

GAWR, front

299.4

660

301.6

665

301.6

665

302.0

665

302.0

665

301.6

665

GAWR, rear

Table 2-5. Capacities: XL 883 Models

XL 883N

XL 883L

XL 883R

ITEM

METRIC

U.S.

METRIC

U.S.

METRIC

U.S.

12.5 L

3.3 gal

17.0 L

4.5 gal

12.5 L

3.3 gal

Fuel tank (total)

2.6 L

2.8 qt

2.6 L

2.8 qt

2.6 L

2.8 qt

Oil tank with filter

0.95 L

1.0 qt

0.95 L

1.0 qt

0.95 L

1.0 qt

Transmission (approximate)

3.0 L

0.8 gal

3.8 L

1.0 gal

3.0 L

0.8 gal

Low fuel warning light

Table 2-6. Capacities: XL 1200 Models and XR 1200X

XR 1200X

XL 1200X/V

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

ITEM

METRIC

U.S.

METRIC

U.S.

METRIC

U.S.

13.2 L

3.5 gal

7.9 L

2.1 gal

17.0 L

4.5 gal

Fuel tank (total)

2.6 L

2.8 qt

2.6 L

2.8 qt

2.6 L

2.8 qt

Oil tank with filter

0.95 L

1.0 qt

0.95 L

1.0 qt

0.95 L

1.0 qt

Transmission
(approximate)

3.0 L

0.8 gal

2.5 L

0.65 gal

3.8 L

1 gal

Low fuel warning light

Table 2-7. Brake Disc Specifications: XL Models

SPECIFICATION

292

11.500

Diameter (front)

260

10.236

Diameter (rear)

5.08

0.200

Minimum thickness (front)

5.84

0.230

Minimum thickness (rear)

0.20

0.008

Maximum disc runout (front and rear)

Table 2-8. Brake Disc Specifications: XR 1200X

SPECIFICATION

292

11.500

Diameter (front)

260

10.236

Diameter (rear)

4.75

0.187

Minimum thickness (front)

5.84

0.230

Minimum thickness (rear)

0.15

0.006

Maximum disc runout (front and rear)

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2-10 2013 Sportster Service: Chassis

Wheels and Tires

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)

Table 2-9. Tubeless Cast Wheels: Tire Fitment

SPECIFIED TIRE

RIM SIZE

AND CONTOUR

WHEEL SIZE

AND POSITION

MODEL

SIZE

TYPE

120/70ZR18

Michelin Scorcher "11F"

T18 x 3.5 MT

18 in - front

XL 883L

150/60ZR17

Michelin Scorcher "11"

T17 x 4.5 MT

17 in - rear

100/90B19

Michelin Scorcher "31"

T19 x 2.15 MT

19 in - front

XL 883R
XL 883N

150/80B16

Michelin Scorcher "31"

T16 x 3.00 D

16 in - rear

XL 883R
XL 883N

130/90B16

Michelin Scorcher "31"

T16 x 3.00 MT

16 in - front

XL 1200C/C ANV
XL 1200CP/CA

150/80B16

Michelin Scorcher "31"

T16 x 3.00 MT

16 in - rear

120/70ZR18

Michelin Scorcher "11F"

E18 x 3.5 MT

18 in - front

XR 1200X

180/55ZR17

Michelin Scorcher "11"

E17 x 5.5 MT

17 in - rear

Table 2-10. Tube Type Steel Laced Wheels: Tire Fitment

SPECIFIED TIRE

TUBE SIZE

RIM SIZE

AND CONTOUR

WHEEL

MODEL

SIZE

TYPE

130/90B16

Michelin Scorcher "31"

MT90-16

T16 x 3.00 D

16 in - front

XL 1200X

150/80B16

Michelin Scorcher "31"

MT90-16

T16 x 3.00 D

16 in - rear

XL 1200X

MH90 21 M/C 54H WW

Dunlop D402F

MH90-21

T21 x 2.15 TLA

21 in - front

XL 1200V

150/80/B16 16 M/C 71H WWW

Dunlop D401

MT/MU90-16

T16 x 3.00 D

16 in - rear

130/90B16

Michelin Scorcher "31"

MT90-16

T16 x 3.00 D

16 in - front

XL 1200C/C
ANV/CP/CB

150/80B16

Michelin Scorcher "31"

MT90-16

T16 x 3.00 D

16 in - rear

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2013 Sportster Service: Chassis 2-11

2.3

VEHICLE IDENTIFICATION NUMBER (VIN)

General

See

Figure 2-2

. A unique 17-digit serial or Vehicle Identification

Number (VIN) is assigned to each motorcycle. Refer to

Table 2-11

Location

See

Figure 2-1

. The full 17-digit VIN is stamped on the right

side of the frame near the steering head. In some destinations,
a printed VIN label is also attached to the right front downtube.

Abbreviated VIN

An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.

NOTE

Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.

om00848c

1. Stamped VIN
2. VIN label

Figure 2-1. VIN Locations: Sportster Models

1HD 4 CS 2 1 3 D C 111000

om00895e

Figure 2-2. Typical Harley-Davidson VIN: 2013 Sportster Models

Table 2-11. Harley-Davidson VIN Breakdown: 2013 Sportster Models

POSSIBLE VALUES

DESCRIPTION

POSITION

1HD=Originally manufactured for sale

within

the United States

World manufacturer identifier

5HD=Originally manufactured for sale

outside

of the United States

932=Originally manufactured in and for sale only in Brazil market
MEG=Originally manufactured in and for sale only in India market

1=Heavyweight motorcycle (901 cm

or larger)

Motorcycle type

4=Middleweight motorcycle (351 cm

to 900 cm

)

See VIN model table

Model

2=Evolution

883 cm

air-cooled, fuel-injected

Engine type

3=Evolution

1202 cm

air-cooled, fuel-injected

6=Evolution

1202 cm

precision-cooled, fuel-injected

HOME

2-12 2013 Sportster Service: Chassis

Table 2-11. Harley-Davidson VIN Breakdown: 2013 Sportster Models

POSSIBLE VALUES

DESCRIPTION

POSITION

Mid-year or Special Introduction

Normal Introduction

Introduction date/Configuration and
calibration recognition

2, 4=Domestic (DOM)

1=Domestic (DOM)

5, 6=California (CAL)

3=California (CAL)

B=Canada (CAN)

A=Canada (CAN)

D=HDI

C=HDI

F=Japan (JPN)

E=Japan (JPN)

H=Australia (AUS)

G=Australia (AUS)

K=Brazil (BRZ)

J=Brazil (BRZ)

M=Asia Pacific (APC)

L=Asia Pacific (APC)

P=India (IND)

N=India (IND)

Can be 0-9 or X

VIN check digit

D=2013

Model year

C=Kansas City, MO U.S.A.

Assembly plant

D=H-D Brazil-Manaus, Brazil (CKD)
N=Haryana India (Bawal District Rewari)

Varies

Sequential number

Table 2-12. VIN Model Codes: 2013 Sportster Models

NAME

MODEL

CODE

NAME

MODEL

CODE

Iron 883

™

XL 883N

SuperLow

XL 883L

Seventy-Two

™

XL 1200V

883 Roadster

XL 883R

1200 Custom

XL 1200CP

1200 Custom

XL 1200C

XL 1200C ANV

1200 Custom Limited A

XL 1200CA

Forty-Eight™

XL 1200X

1200 Custom Limited B

XL 1200CB

XR1200X™

XR 1200X

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2013 Sportster Service: Chassis 2-13

2.4

TIRES

REMOVAL

NOTE

Take care when removing and installing tire to prevent cosmetic
damage to wheel. This is especially true with wheels that fea-
ture painted surfaces.

Remove wheel from motorcycle. See

2.5 WHEELS, Front

Wheel

2.5 WHEELS, Rear Wheel

Deflate tire.

NOTE

Tube Type Wheels: do not completely remove tire from rim
to replace the tube only. Removing one side allows the tube
to be replaced and allows for inspection of tire.

Loosen both tire beads from rim flange. Use a bead
breaker machine if available.

Remove tire.

CLEANING, INSPECTION AND REPAIR

Clean the inside of tire and outer surface of tube.

If rim is dirty or rusty, clean with a stiff wire brush.

Check wheels for lateral and radial runout before installing
a tire. See

2.7 CHECKING AND TRUING WHEELS

Inspect the tire for wear and damage.

Inspect tread depth. Replace worn tires.

Replace tube and rim seal prior to installing tire.

Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)

Repair tread on tubeless tires if puncture is 1/4 in (6.4 mm)
or smaller. Repairs must be made from inside the tire.

Always combine a patch and plug when repairing damaged
tires.

INSTALLATION

TORQUE VALUE

FASTENER

0.3-0.8 Nm

3-7

in-lbs

Valve stem, tube type, nut

1.4-1.7 Nm

12-15

in-lbs

Valve stem, tubeless type, nut

Mounting

Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)

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)

Mount tires with arrows molded into the tire sidewall with the
arrow pointing in the direction of forward rotation.

Locate the colored balance dot on the sidewall next to the valve
stem.

For tire pressures, see

1.8 TIRES AND WHEELS, Air Pressure

Tube Type 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)

NOTES

•

Replace the tube whenever the tire is replaced.

•

Only patch inner tubes as an emergency measure.
Replace a patched tube as soon as possible.

•

For correct tire and tube types, see

1.8 TIRES AND

WHEELS, Specified Tires

HOME

2-14 2013 Sportster Service: Chassis

See

Figure 2-3

. On laced wheels, install a rim strip into

the rim well.

Verify that the spokes do not protrude through the
nipples.

Align the valve stem hole in rim strip with valve stem
hole in rim.

Install tube and tire.

Install valve stem nut. Tighten to 3-7

in-lbs

(0.3-0.8 Nm).

sm02466

Figure 2-3. Installing Rim Strip

Tubeless Tires

Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)

See

Figure 2-4

. Replace damaged or leaking valve stems.

XL 883L/N/R Cast Wheels:

Install rubber grommet (5) on valve stem (1).

Insert valve stem into rim hole.

Install metal washer (4).

Install nut (3). Tighten to 12-15

in-lbs

(1.4-1.7 Nm).

XL 1200C/C ANV/CP/CA Cast Wheels:

Press the snap-

in valve stem (2) into the rim hole.

Install tire.

sm07581

1. Bolt-on valve stem
2. Snap-in valve stem
3. Nut
4. Metal washer
5. Rubber grommet

Figure 2-4. Tubeless Tire Valve Stems

CHECKING TIRE RUNOUT

Lateral Runout

Check tire pressure.

See

Figure 2-5

. Turn the wheel on the axle and measure

tire lateral runout from a fixed point to a smooth area on
the tire sidewall. Avoid measuring on raised letters or
vents.

Tire lateral runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds specification, remove tire from rim
and check rim lateral runout. See

2.7 CHECKING AND

TRUING WHEELS

If rim lateral runout is within specification, the tire is
at fault and must be replaced.

If rim lateral runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See

2.7 CHECKING AND

TRUING WHEELS

Install the tire. Check tire lateral runout of replacement
tire.

HOME

2013 Sportster Service: Chassis 2-15

sm01803a

Figure 2-5. Tire Lateral Runout

Radial Runout

Check tire pressure.

See

Figure 2-6

. Turn the wheel on the axle and measure

tire radial runout at the tread centerline.

Tire radial runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds this specification, remove tire from
rim and check rim radial runout.See

2.7 CHECKING AND

TRUING WHEELS

If rim radial runout is within specification, the tire is at
fault and must be replaced.

If rim radial runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See

2.7 CHECKING AND

TRUING WHEELS

Install the tire. Check tire radial runout of replacement tire.

sm01804a

Figure 2-6. Tire Radial Runout

WHEEL BALANCING

NOTE

Install tire after balancing. See See

2.5 WHEELS, Front Wheel

2.5 WHEELS, Rear Wheel

Static vs Dynamic

Wheel balancing is recommended to improve handling. Balan-
cing wheels reduces vibration especially at high speeds.

Static balancing will produce satisfactory results for normal
highway speeds. Dynamic balancing can produce better results
for deceleration.

Weights

The maximum weight permissible to accomplish balance is 3.5
oz (99.2 g) (total weight applied to the rim). If more than 3.5
oz (99.2 g) of weight is required, rotate the tire 180 degrees
on the rim and again balance the assembly. Balance wheels
to within 0.5 oz (14 g).

All wheel weights currently supplied by Harley-Davidson are
made from zinc which is lighter than lead. The weight of each
zinc segment is 0.18 oz (5 g) as compared to 0.25 oz (7 g) for
lead. Weights are stamped for easy identification.

NOTES

•

If adding more than 1.5 oz (43 g) of weight at one location,
divide the amount so that half is applied to each side of
rim.

•

On cast wheels without a flat area near the bead, place
the weights crosswise through the opening.

See

Figure 2-8

. Place weights on a smooth surface of the

wheel rim such that centrifugal force will help keep them
in place. Make sure the area of application is completely
clean, dry, and free of oil and grease.

NOTE

See

Figure 2-7

. When installing wheel weights, consider cos-

metics. Keep snaking (1) within 0.040 in (1.02 mm) (2) of
straight. Also keep the angle alignment of individual segments
(3) within 3 degrees.

Remove paper backing from the weight. Press firmly in
place and hold for ten seconds.

sm07192b

1. Snaking
2. Not to exceed 0.040 in (1.02 mm)
3. Not to exceed 3 degree

Figure 2-7. Weight Segment Alignment

HOME

2-16 2013 Sportster Service: Chassis

2.5

WHEELS

GENERAL

TORQUE VALUE

FASTENER

81-88 Nm

60-65 ft-lbs

Axle, front, nut

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

Good handling and maximum tire mileage are directly related
to the care of wheels and tires. Regularly inspect wheels and

tires for damage and wear. If handling problems occur, see

1.28 TROUBLESHOOTING

or refer to

Table 2-13

for a list of

probable causes.

Keep tires inflated to the recommended air pressure. Always
balance the wheel after replacing a tube or tire.

Table 2-13. Wheel Service Chart

REMEDY

CHECK FOR

Tighten front axle nut to 60-65 ft-lbs (81-88 Nm).

Loose axle nuts.

Tighten rear axle nut to 95-105 ft-lbs (129-142 Nm).

Replace wheel hub bearings. See

2.5 WHEELS, Sealed Wheel

Bearings

Excessive side-play or radial (up-and-down) play in wheel hubs.

Tighten or replace spokes. See

2.6 WHEEL LACING

and

2.7 CHECKING AND TRUING WHEELS

Loose spokes.

Check rear wheel alignment as described in this section or repair
rear fork as described in

2.23 REAR FORK

Alignment of rear wheel in frame or with front wheel.

True wheels, replace rims or replace spokes. See

2.6 WHEEL

LACING

and

2.7 CHECKING AND TRUING WHEELS

Rims and tires lateral runout more than 1/32 in (0.76 mm).

Rims and tires vertical runout not be more than 1/32 in (0.76
mm).

Replace as described in

2.5 WHEELS

and

2.4 TIRES

Irregular or peaked front tire wear.

Inflate tires to correct pressure. See

1.8 TIRES AND WHEELS

Correct tire inflation.

Static balance may be satisfactory if dynamic balancing facilities
are not available. However, dynamic balancing is strongly
recommended.

Correct tire and wheel balance.

Replace pitted or worn bearings. Adjust fall-away. See

2.21 FORK STEM AND BRACKET ASSEMBLY

Steering head bearings.

Check for leaks. See

2.19 FRONT FORK: XL MODELS

2.20 FRONT FORK: XR 1200X

Damper tubes.

Check damping action and mounting stud bushings. See

2.24 SHOCK ABSORBERS

Shock absorbers.

Check for looseness. See

2.23 REAR FORK

Rear fork bearings.

WHEEL BEARING END PLAY

Raise the wheel off the ground.

See

Figure 2-9

. Mount a magnetic base dial indicator on

the brake disc.

Set the indicator contact point on the end of the axle.

Move the wheel back as far as it will go. Hold the wheel
in position and zero the dial indicator.

Move the wheel forward as far as it will go. Note the
reading of the dial indicator. Verify the reading.

If end play is greater than specification, remove the wheel
and replace both wheel bearings. Refer to

Table 2-14

HOME

2-18 2013 Sportster Service: Chassis

sm01778

1. Magnetic base
2. Brake disc
3. Axle
4. Dial indicator

Figure 2-9. Check Wheel Bearing End Play

Table 2-14. Wheel Bearing End Play

DIRECTION

0.05

0.002

Lateral

FRONT WHEEL

TORQUE VALUE

FASTENER

21.7-32.6 Nm

16-24 ft-lbs

Hub plate mounting screw

21.7-32.6 Nm

16-24 ft-lbs

Brake disc, front, screw

21.7-32.6 Nm

16-24 ft-lbs

Brake disc, front, screw

21.7-32.6 Nm

16-24 ft-lbs

Brake disc, front, screw

21.7-32.6 Nm

16-24 ft-lbs

Brake disc, front, screw

81-88 Nm

60-65 ft-lbs

Axle, front, nut

28.5-36.6 Nm

21-27 ft-lbs

Axle, front, pinch screw: XL
Models

55.6-65.1 Nm

41-48 ft-lbs

Axle, front, pinch screw: XR
1200X

Removal

Raise the front wheel off the ground.

NOTES

•

Do not operate the front brake lever with the front wheel
removed or the caliper pistons may be forced out. Seating
the pistons requires disassembly of the caliper.

•

On models with dual disc brakes, remove both calipers.

See

Figure 2-10

. Remove brake caliper mounting screws

(3). Slide caliper (4) off brake disc and secure caliper out
of the way.

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

Remove the front fender.

See

2.31 FRONT FENDER

Remove axle nut (1) and flat washer (2) from axle on left
side of vehicle.

See

Figure 2-11

. On right side of vehicle, loosen nut (4)

on pinch screw (1). Pull axle out of hub while supporting
wheel.

Remove spacer and front wheel assembly.

sm07127

1. Axle nut
2. Flat washer
3. Brake caliper mounting screws
4. Brake caliper

Figure 2-10. Left Side Front Wheel Mounting

sm07126

1. Pinch screw
2. Washer
3. Lockwasher
4. Nut
5. Axle

Figure 2-11. Right Side Front Wheel Mounting

Disassembly: Cast Front Wheel

If necessary, remove tire. See

2.4 TIRES

Remove five screws and left side brake disc.

HOME

2013 Sportster Service: Chassis 2-19

If necessary, remove five screws and right side brake disc
(dual front disc models) or hub plate (single front disc
models).

If necessary, remove roller bearings and hub spacer. See

2.5 WHEELS, Sealed Wheel Bearings

Assembly Cast Single Disc

Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)

See

Figure 2-12

. Install hub spacer (7) and

new

wheel

bearings (6). See

2.5 WHEELS, Sealed Wheel Bearings

XL 883N:

Install hub plate (8) on right side of wheel.

Secure with

new

screws and tighten in an alternating

pattern to 16-24 ft-lbs (21.7-32.6 Nm).

NOTE

See

Figure 2-13

. Orient brake discs with the word LEFT (1)

facing out. Verify that the bulb shaped end (2) of the slots points
opposite the direction of rotation (3).

Install brake disc. Secure with

new

screws and tighten in

an alternating pattern to 16-24 ft-lbs (21.7-32.6 Nm).

sm07574

1. Axle
2. Nut
3. Washer
4. Wide spacer
5. Narrow spacer
6. Bearings (2)
7. Hub spacer
8. Hub plate: XL 883N
9. Fastener (10)
10. Brake disc
11. XL 883N
12. XL 883L
13. XL 1200C/C ANV/CP/CA

Figure 2-12. Single Disc Wheels: XL Models

HOME

2-20 2013 Sportster Service: Chassis

sm07576

1. Left
2. Slot bulb end
3. Direction of rotation

Figure 2-13. Single Disc Orientation

Assembly Cast Dual Disc: XL 883R

See

Figure 2-14

. Install hub spacer (7) and

new

wheel

bearings (6). See

2.5 WHEELS, Sealed Wheel Bearings

NOTE

See

Figure 2-15

. The words LEFT (1) and RIGHT (2) on the

discs will be located on the left and right sides.

Hold brake discs together with inboard sides facing each
other (minimum thickness and part number stampings are
on outboard side of brake disc). The bulb shaped end (3)
of each slot is on the trailing edge of the slot in the direc-
tion of rotation (4).

Rotate one brake disc as necessary, until all vent holes
are aligned with those of the other brake disc.

Keeping the paint marks on the edge of both discs aligned,
install both brake discs onto hub. Secure with

new

screws.

Holding brake discs aligned, use a felt marking pen or
paint pen to draw a line across the edge of both brake
discs.

Tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6
Nm).

Verify that wheel is true. See

2.7 CHECKING AND

TRUING WHEELS, Cast Wheel Runout

sm07573

1. Axle
2. Nut
3. Washer
4. Wide spacer
5. Narrow spacer
6. Bearing (2)
7. Hub spacer
8. Fastener (10)
9. Brake disc (2)

Figure 2-14. Dual Disc Wheel: XL 883R

sm07570

1. Left
2. Right
3. Slot bulb end
4. Direction of rotation

Figure 2-15. Dual Disc Orientation: XL 883R

HOME

2013 Sportster Service: Chassis 2-21

Assembly Cast Dual Disc: XR 1200X

See

Figure 2-16

. . XR 1200X models are equipped with a

floating front brake disc. They are non-directional and do not
need to be matched with opposite disc.

Tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6 Nm).

sm07572

1. Axle
2. Nut
3. Washer
4. Spacer (2)
5. Bearing (2)
6. Hub spacer
7. Fastener (10)
8. Brake disc (2)

Figure 2-16. Dual Disc Wheel: XR 1200X

Disassembly: Laced Front Wheel

See

Figure 2-17

. If necessary, remove five screws (1) and

brake disc (9).

If necessary, remove wheel bearings (4) and hub spacer
(6). See

2.5 WHEELS, Sealed Wheel Bearings

NOTE

If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels. See

2.6 WHEEL LACING

and

2.7 CHECKING AND TRUING WHEELS

If it is necessary to disassemble wheel, loosen spoke
nipples and spokes and slide each spoke out of hub.

Assembly: Laced Front Wheel

See

Figure 2-17

. Install hub spacer (6) and

new

wheel

bearings (4) if removed. See

2.5 WHEELS, Sealed Wheel

Bearings

If hub and rim were disassembled, reassemble and true
wheel. See

2.6 WHEEL LACING

and

2.7 CHECKING AND

TRUING WHEELS

Install brake disc (9). Secure with

new

screws (1) and

tighten in an alternating pattern to 16-24 ft-lbs (21.7-32.6
Nm).

Verify that wheel is true.

sm01777g

1. Screw
2. Washer
3. Nut
4. Roller bearing
5. Bearing spacer, narrow
6. Hub spacer
7. Bearing spacer, wide
8. Front axle
9. Brake disc
10. Wheel: 16 in XL 1200X/CP/CB certain markets
11. Wheel: 21 in XL 1200V

Figure 2-17. Laced Front Wheel

Installation

Apply a light coat of ANTI-SEIZE LUBRICANT to the axle,
bearing bores, and hub spacer bore.

Position wheel between forks. Verify that bearing spacers
on right and left side of wheel bearings are in position.

HOME

2-22 2013 Sportster Service: Chassis

With pinch screw loose, insert threaded end of axle
through right side fork. Push axle through fork and wheel
hub until it begins to emerge from left side of hub.

Push axle through left fork, until axle shoulder contacts
external bearing spacer on right fork side.

Install flat washer and axle nut over threaded end of axle.
Insert screwdriver or steel rod through hole in axle on right
side of vehicle. While holding axle stationary, tighten axle
nut to 60-65 ft-lbs (81-88 Nm).

Dual Disc Models:

Align calipers to brake discs:

Make sure axle pinch screw nut is loose.

Position right fork leg against bearing spacer.

XL Models:

Tighten axle pinch screw to 21-27 ft-lbs

(28.5-36.6 Nm).

XR 1200X:

Tighten axle pinch screw to 41-48 ft-lbs

(55.6-65.1 Nm).

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

Install front fender. See

2.31 FRONT FENDER

Install brake caliper(s). See

2.9 FRONT BRAKE CALIPER:

XL MODELS

2.10 FRONT BRAKE CALIPER: XR

1200X

Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling and can cause loss of control, which
could result in death or serious injury. (00285b)

Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury. (00284a)

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

REAR WHEEL

TORQUE VALUE

FASTENER

40.7-61.1 Nm

30-45 ft-lbs

Brake disc, rear, screw

81.3 Nm

60 ft-lbs

Sprocket mounting screw, 1st
torque

108.0 Nm

80 ft-lbs

Sprocket mounting screw, final
torque

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

Removal

Secure motorcycle upright on a suitable lift. Raise rear
end of motorcycle high enough to permit wheel removal.

XL Models:

Remove rear muffler. See

4.13 EXHAUST

SYSTEM: XL MODELS

XL Models:

Remove right lower shock absorber nut and

pull screw out slightly. This will help avoid damage to
sprocket when rear wheel is removed.

See

Figure 2-18

. Remove E-clip (2), axle nut (1) and

washer (3).

Loosen adjuster screws several turns to relieve belt ten-
sion.

Gently tap end of axle (4) with a soft hammer to loosen.
Pull axle free of rear fork assembly.

Slide wheel forward and slip belt off sprocket.

NOTE

It is not necessary to disassemble rear brake caliper in order
to remove rear wheel.

XR 1200X:

Disengage brake hose from clamps on lower

side of rear fork. Carefully slide caliper and bracket
assembly forward to disengage from brake disk and boss
on rear fork. Support assembly from frame using rope or
bungee cord.

Remove spacers and roll rear wheel assembly back out
of fork.

10. Remove rear wheel assembly.

NOTE

Do not operate rear brake pedal with rear wheel removed or
caliper piston may be forced out of piston bore. Seating piston
requires disassembly of caliper.

sm03593b

1. Axle nut
2. E-clip
3. Washer
4. Rear axle

Figure 2-18. Rear Wheel Mounting

Disassembly

NOTES

•

Sportster models sold in certain markets are equipped
with rear wheel compensating sprockets. See

C.1 COM-

PENSATING SPROCKET

•

Mark parts to indicate location. Do not mix parts upon
assembly.

If necessary, remove tire. See

2.4 TIRES

HOME

2013 Sportster Service: Chassis 2-23

See

Figure 2-19

Figure 2-20

. If necessary, remove

screws to detach rear brake disc from left side of wheel.

If necessary, remove screws and washers to detach rear
sprocket from right side of wheel.

If necessary, remove wheel bearings and hub spacer. See

2.5 WHEELS, Sealed Wheel Bearings

NOTE

Laced Wheel: If only rim is to be replaced, tape spokes
together to hold position on hub and remove spokes from rim.
See

1.12 DRIVE BELT AND SPROCKETS

Laced Wheel:

If it is necessary to disassemble wheel,

loosen the spoke nipples and spokes and slide each spoke
out of hub.

Cleaning and Inspection

Inspect all parts for damage or excessive wear.

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

Inspect brake pads and disc. See

1.16 BRAKE PADS AND

DISCS: XL MODELS

1.17 BRAKE PADS AND DISCS:

XR 1200X

Inspect rear belt and sprocket. See

1.12 DRIVE BELT

AND SPROCKETS

Assembly

Laced Wheel:

if wheel was disassembled, reassemble

hub, rim, spokes and nipples, and tighten spokes. See

1.12 DRIVE BELT AND SPROCKETS

Install hub spacer and

new

wheel bearings, if removed.

See

2.5 WHEELS, Sealed Wheel Bearings

Cast or disc wheel:

See

Figure 2-19

Laced wheel:

See

Figure 2-20

If brake disc was removed, install brake disc on valve stem
side of wheel. Secure with

new

screws and tighten to 30-

45 ft-lbs (40.7-61.1 Nm).

NOTE

Sportster models sold in certain markets are equipped with
rear wheel compensating sprockets. See

C.1 COMPENSATING

SPROCKET

If rear sprocket was removed, install sprocket on side of
wheel opposite valve stem.

Secure with

new

screws and washers. Tighten to 60

ft-lbs (81.3 Nm).

Loosen each screw 180 degrees and tighten to 80 ft-
lbs (108.0 Nm).

Verify that wheel assembly is true. See

2.7 CHECKING

AND TRUING WHEELS

Install tire. See

2.4 TIRES

sm07577

1. E-clip
2. Screw (5)
3. Washer
4. Washer (5)
5. Axle nut
6. Roller bearing (2)
7. Sprocket
8. Spacer, wide
9. Spacer, narrow
10. Brake disc
11. Axle
12. Hub spacer
13. Screw (5)
14. Wheel: 16 in XL 1200C/C ANV/CP/CA (certain

markets)

15. Wheel: 16 in XL 883N/R
16. Wheel: 17 in XL 883L
17. Wheel: 17 in XR 1200X

Figure 2-19. Cast Rear Wheel

HOME

2-24 2013 Sportster Service: Chassis

Harley Davidson 2013 Sportster Models. Service Manual - page 12