Harley Davidson 2013 Sportster Models. Service Manual

sm07578

1. E-clip
2. Axle nut
3. Washer
4. Fastener
5. Spacer
6. Brake disc
7. Roller bearing (2)
8. Wheel: 16 in XL 1200X/V/CP/CB and XL 1200C/C

ANV/CA certain markets

9. Spacer, wide
10. Sprocket
11. Spacer, narrow
12. Washer
13. Fastener
14. Axle

Figure 2-20. Laced Rear Wheel

Installation

See

Figure 2-19

Figure 2-20

. Apply a light coat of ANTI-

SEIZE LUBRICANT to the axle, bearing bores, and hub
spacer bore.

Place wheel centrally in the rear fork assembly. Engage
the brake disc in the caliper on XL models.

XR 1200X:

With the wheel as far forward as possible,

install the caliper/bracket assembly in place, engaging the
brake disk and the boss on the rear fork.

Slide wheel forward and slip belt over sprocket and then
slide the wheel back.

Position sprocket side spacer between wheel and rear
fork.

Insert axle through right side of rear fork and right side
axle adjuster, sprocket side spacer, wheel assembly, disc
side spacer, rear caliper bracket, and left side of rear fork
and left side axle adjuster.

Install washer and axle nut on left end of axle. Do not
tighten nut at this time.

XL Models:

Slide right lower shock absorber screw back

in place. Install nut and tighten to 45-50 ft-lbs (61-68 Nm).

NOTE

If rear brake caliper was disassembled or removed, see

2.14 REAR BRAKE CALIPER: XL MODELS

2.15 REAR

BRAKE CALIPER: XR 1200X

Check for proper belt tension and rear wheel alignment.
See

1.24 WHEEL ALIGNMENT

10. Tighten axle nut to 95-105 ft-lbs (129-142 Nm). Install E-

clip.

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)

11. Check wheel bearing end play. See

2.5 WHEELS, Wheel

Bearing End Play

12.

XL Models:

Install rear muffler. See

4.13 EXHAUST

SYSTEM: XL MODELS

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)

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

outside brake pad. Verify piston location against pad.

SEALED WHEEL BEARINGS

TOOL NAME

PART NUMBER

WHEEL BEARING
INSTALLER/REMOVER

HD-44060-C

TORQUE VALUE

FASTENER

21.7-32.6 Nm

16-24 ft-lbs

Single caliper cast front wheel
hub plate screw

Inspection

Inspect the play of the wheel bearings by finger while they
are in the wheel. Rotate the inner bearing race and check
for abnormal noise. Make sure bearing rotates smoothly.

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

Removal

If not already done, remove wheel from motorcycle. See

2.5 WHEELS

. On models with a single front brake caliper,

remove hub plate from wheel on side opposite front brake
disc.

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2013 Sportster Service: Chassis 2-25

NOTE

See

Figure 2-21

. Some wheel hubs may not provide adequate

support for the puller bridge. In these cases, center a used
brake disc over the hub to support the puller bridge while
removing the bearing.

SM03870

Figure 2-21. Brake Disk as Puller Aid

See

Figure

2-22

Obtain

WHEEL

BEARING

INSTALLER/REMOVER (Part No. HD-44060-C) and
assemble.

Sparingly apply graphite lubricant to threads of forcing
screw (1) for prolonged service life and smooth
operation.

Install nut (2), washer (3) and bearing (4) on screw.
Insert assembly through hole in bridge (5).

Drop ball bearing inside collet (6). Fasten collet and
ball bearing to forcing screw.

Hold end of forcing screw and turn collet to expand edges
of collet.

See

Figure 2-23

. When expanded collet has gripped

bearing edges, hold end of forcing screw (1) and turn the
nut (2) to remove bearing from wheel.

Remove spacer from inside wheel hub.

Repeat procedure for opposite side bearing. Discard both
bearings upon removal.

sm01685

1. Forcing screw
2. Nut
3. Washer
4. Bearing
5. Bridge
6. Collet with ball bearing inside

Figure 2-22. Wheel Bearing Removal Tool

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2-26 2013 Sportster Service: Chassis

sm01686

1. Forcing screw
2. Nut

Figure 2-23. Removing Bearing

Installation

NOTES

•

When installing wheel bearings, use specialty tool WHEEL
BEARING INSTALLER/REMOVER (Part No. HD-44060-
C).

•

Always install first bearing on primary brake disc side. If
front wheel has two brake discs, install bearing on the left
side first.

Obtain WHEEL BEARING INSTALLER/REMOVER (Part
No. HD-44060-C) and assemble.

Sparingly apply graphite lubricant to threads of
threaded rod for prolonged service life and smooth
operation.

See

Figure 2-24

. Place threaded rod (1) through

support plate (2). Insert assembly through wheel.

See

Figure 2-25

. Place

new

bearing on rod (1) with

lettered side facing out.

Assemble installer (5), bearing (4), washer (3) and
nut (2) over rod.

Hold hex end of threaded rod and turn nut to install wheel
bearing. Bearing is fully seated when nut can no longer
be turned. Remove tool.

Install spacer inside wheel hub.

Reverse tool and install opposite side wheel bearing.

Install hub plate opposite brake disc and secure with

new

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

sm01783

1. Threaded rod
2. Support plate

Figure 2-24. Assembling Installation Tool

sm01688

1. Threaded rod
2. Nut
3. Washer
4. Bearing
5. Installer
6. Wheel bearing

Figure 2-25. Installing Bearing

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2013 Sportster Service: Chassis 2-27

2.6

WHEEL LACING

WHEEL LACING: ANGLE FLANGE HUB

NOTES

•

See

Figure 2-26

. The following procedure is valid for

wheels that use an angle flange hub regardless of rim
style or diameter.

•

The primary brake side of the hub has one or two grooves
cut into the disc mounting surface.

sm06505

1. Outer spoke hole
2. Inner spoke hole

Figure 2-26. Angle Flange Hub

Place hub on workbench:

Front:

primary brake side up.

Rear:

brake side down.

Install all spokes in the lower flange.

See

Figure 2-27

. Flip hub over. Gather all outer spokes

and hold upright with a rubber band. Repeat with the inner
spokes using a second rubber band.

Install spokes in remaining flange.

Rotate the lower flange spokes as far as they will go:

Outer spokes clockwise.

Inner spokes counterclockwise.

Center the rim over the hub and spokes assembly and
support on wooden blocks approximately 1.5 in (38.1 mm)
thick.

If valve is not located in the center of the rim, place
valve hole facing up.

If the valve located in the center of the rim can be
placed either side up.

NOTE

Install nipples until approximately 1/8 in (3.2 mm) of spoke
thread shows.

sm06503

1. Outer spoke
2. Inner spoke

Figure 2-27. Spokes Gathered

Install lower flange outer spokes and loosely install spoke
nipples:

Rim with side valve hole:

See

Figure 2-28

. Start at

the valve stem hole (1).

Rim with center valve hole:

See

Figure 2-29

. Start

at the first hole counterclockwise (1) from valve stem
hole.

Install remaining outer spokes in every 4th hole.

Install lower flange inner spokes and loosely install spoke
nipples:

Starting at the 2nd hole counterclockwise (2) from
first spoke installed, install inner spoke.

Install remaining inner spokes in every 4th hole.

10. Carefully release upper flange inner spokes and fan out

around rim, rotating them clockwise.

11. Starting at the first hole counterclockwise (3) from first

spoke installed, install inner spoke. Install all remaining
inner spokes in every 4th hole.

12. Carefully release upper flange outer spokes and fan out

around rim, rotating them counterclockwise.

13. Install outer spokes in remaining holes (4).

14. Verify spoke heads are seated. See

2.7 CHECKING AND

TRUING WHEELS

Evenly hand-tighten spoke nipples until snug.

Only tighten until slack is removed.

Proper torque will be applied when the wheel is trued.

Adjust offset and true the wheel.

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2-28 2013 Sportster Service: Chassis

sm06506

Figure 2-28. Side Valve Rim

sm06507

Figure 2-29. Center Valve Rim

WHEEL LACING: STRAIGHT FLANGE HUB,
SINGLE HOLE CIRCLE

NOTES

•

See

Figure 2-31

. The following procedure is valid for laced

wheels that use a straight flange, single spoke hole circle
hub regardless of rim style or diameter.

•

The primary brake side of the hub has one or two grooves
cut into the disc mounting surface.

See

Figure 2-30

. Divide spokes into inner and outer

groups.

Inner spokes (2) have long heads.

Outer spokes (1) have short heads.

Lubricate all spoke threads and nipple shoulders with tire
mounting lubricant.

Place hub on bench with the primary brake disc side up.

Fit the first two spokes.

See

Figure 2-31

. Insert one outer spoke (1) (short

head) into any bottom flange hole and swing it clock-
wise.

Insert an inner spoke (2) (long head) in the next hole
counterclockwise from the outer spoke.

Swing the inner spoke counterclockwise over the
outer spoke.

Find the hole (3) in the upper flange directly above the
first two spokes. Insert a long head inner spoke.

Insert all remaining spokes in the upper flange, alternating
the inner and outer spokes.

Flip the hub (primary brake side down). Install remaining
spokes alternating inner and outer spokes.

See

Figure 2-32

. Group all spokes on the upper flange

into two bundles of equal numbers. Secure each group
with throttle grips.

sm06086

1. Short head (outer spoke)
2. Long head (inner spoke)

Figure 2-30. Spoke Heads

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2013 Sportster Service: Chassis 2-29

sm02245

1. Outer spoke (short head)
2. Inner spoke (long head)
3. Hole directly above two spokes

Figure 2-31. Lacing Single Row Wheel Hub

sm02246

Figure 2-32. Bundling Top Spokes

NOTE

Outer spokes must not cross an outer spoke. Inner spokes
must not cross an inner spoke.

Angle all lower flange spokes as far as they will go without
overlapping a LIKE spoke:

Outer spokes (short head) clockwise.

Inner spokes (long head) counterclockwise.

10. Support the rim on wooden blocks approximately 0.75 in

(19 mm) thick.

11. Place the hub and spoke assembly into the rim and

centered in the rim.

NOTE

Install nipples until approximately 1/8 in (3.2 mm) of spoke
thread shows.

12. See

Figure 2-33

. Beginning with the 2nd hole counterclock-

wise (1) from valve stem hole, install lower flange outer
spokes (short head) in every 4th hole. Loosely install spoke
nipples.

sm06508

Figure 2-33. 40 Spoke Single Row Straight Flange Hub

sm07125

Figure 2-34. 32-Spoke Single Row Straight Flange Hub

13. Beginning with 4th hole counterclockwise (2) from valve

stem hole, install lower flange inner spokes (long head)
in every 4th hole. Loosely install spoke nipples. Each inner
spoke will cross four outer spokes.

14. See

Figure 2-35

. Carefully release each top bundle and

fan the spokes around the rim edge.

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2-30 2013 Sportster Service: Chassis

sm02252

Figure 2-35. Fanning Top Flange Spokes

15. Rotate all the upper flange inner spokes (long head)

clockwise, one at a time, leaving the outer spokes (short
head) resting on the rim.

NOTE

Be sure outer spokes do not fall under the inner spoke and
become trapped.

16. See

Figure 2-33

. Beginning with the first hole counterclock-

wise (3) from valve stem hole, install upper flange inner
spokes (long head) in every 4th hole.

17. Rotate outer spokes (short head) counterclockwise and

install in the remaining holes (4) in the rim.

18. Verify spoke heads are seated. Evenly hand-tighten spoke

nipples until snug. Only tighten until slack is removed.

19. Adjust rim offset and true the wheel. Tighten the nipples

to specification. See

2.7 CHECKING AND TRUING

WHEELS

WHEEL LACING: STRAIGHT FLANGE HUB,
DUAL HOLE CIRCLE

NOTES

•

See

Figure 2-37

. This procedure is valid for 40-spoke

wheels that use a straight flange, dual spoke hole circle
hub regardless of rim style or diameter.

•

The primary brake side of the hub has one or two grooves
cut into the disc mounting surface.

See

Figure 2-36

. Divide spokes into inner and outer

groups.

Inner spokes (2) have long heads.

Outer spokes (1) have short heads.

Lubricate all spoke threads and nipple shoulders with tire
mounting lubricant.

Place hub on bench with the primary brake disc side up.

Install first two spokes:

See

Figure 2-37

. Insert one outer spoke (short head)

into any upper flange outer hole. Swing it counterclock-
wise.

Insert an inner spoke (long head) in the next hole
counterclockwise from the outer spoke.

Swing the inner spoke clockwise under the outer
spoke.

Insert all remaining spokes in the upper flange, alternating
the inner and outer spokes.

Flip the wheel hub (primary brake side down) and install
remaining spokes in the same manner, again alternating
inner and outer spokes.

See

Figure 2-38

. Group all spokes on the upper flange

into two bundles of ten. Secure each group with throttle
grips.

sm06086

1. Short head (outer spoke)
2. Long head (inner spoke)

Figure 2-36. Spoke Heads

sm01787

1. Outer spoke hole
2. Outer spoke (short head)

Figure 2-37. Lacing Dual Row Wheel Hub

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2013 Sportster Service: Chassis 2-31

sm01788

Figure 2-38. Bundling Top Spokes

Angle all lower flange spokes as far as they will go without
overlapping a LIKE spoke (inner must not cross inner;
outer must not cross outer):

Outer spokes (short head) clockwise.

Inner spokes (long head) counterclockwise. All inner
spokes lay over outer spokes.

Support the rim on wooden blocks approximately 0.75 in
(19 mm) thick.

10. Place the hub and spoke assembly into the rim and

centered in the rim.

NOTE

Install nipples until approximately 1/8 in (3.2 mm) of spoke
thread shows.

11. See

Figure 2-39

. Beginning with the 1st hole counterclock-

wise (1) from valve stem hole, install lower flange outer
spokes (short head) in every 4th hole. Loosely install spoke
nipples.

sm06509

Figure 2-39. Flat Flange Hub, Dual Row

12. Beginning with 3rd hole counterclockwise (2) from valve

stem hole, install lower flange inner spokes (long head)
in every 4th hole. Loosely install spoke nipples. Each inner
spoke will cross four outer spokes.

13. See

Figure 2-40

. Carefully release each top bundle and

fan the spokes around the rim edge.

sm07550

Figure 2-40. Fanning Top Flange Spokes

14. Rotate all the upper flange inner spokes (long head)

clockwise, one at a time, leaving the outer spokes (short
head) resting on the rim.

NOTE

Be sure outer spokes do not fall under the inner spoke and
become trapped.

15. See

Figure 2-39

. Beginning with the 2nd hole counterclock-

wise (3) from valve stem hole, install upper flange inner
spokes (long head) in every 4th hole.

16. Rotate outer spokes (short head) counterclockwise. Install

in the remaining holes (4) in the rim.

17. Verify spoke heads are seated. See

2.7 CHECKING AND

TRUING WHEELS

Evenly hand-tighten spoke nipples until snug.

Only tighten until slack is removed.

Proper torque will be applied when the wheel is trued.

Adjust offset and true the wheel.

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2-32 2013 Sportster Service: Chassis

2.7

CHECKING AND TRUING WHEELS

CAST WHEEL RUNOUT

TOOL NAME

PART NUMBER

WHEEL TRUING AND BALANCING
STAND

HD-99500-80

Wheel Stand

Check the wheel bearings before measuring runout. See

2.5 WHEELS, Sealed Wheel Bearings

Install the truing arbor in the wheel hub and mount the
wheel in a WHEEL TRUING AND BALANCING STAND
(Part No. HD-99500-80).

Tighten the arbor nuts so that the hub will turn on its
bearings.

Mount a gauge rod or a dial indicator to the base of the
truing stand.

Lateral Runout

See

Figure 2-41

. Point the gauge rod or indicator at the

rim bead flange.

Rotate the wheel and measure the lateral distance at
several locations around the rim. Replace the wheel if
lateral runout exceeds specification. Refer to

Table 2-15

Radial Runout

See

Figure 2-42

. Point the gauge rod or indicator at the

rim tire bead safety hump.

Rotate the wheel and measure radial distance at several
locations. Replace the wheel if radial runout exceeds
specification. Refer to

Table 2-15

Table 2-15. Wheel Rim Runout

RUNOUT

0.76

0.030

Lateral

0.76

0.030

Radial

sm05340a

Figure 2-41. Lateral Runout

sm05341a

Figure 2-42. Radial Runout

LACED WHEEL RIM OFFSET

TOOL NAME

PART NUMBER

SPOKE NIPPLE WRENCH

HD-94681-80

WHEEL TRUING STAND

HD-99500-80

See

Figure 2-43

. Place a piece of tape to mark the center

of each group of four spokes as shown. The groups should

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2013 Sportster Service: Chassis 2-33

be directly opposite one another and approximately 90
degrees apart. Using different colors of tape or numbering
each group is helpful.

sm01235

Figure 2-43. Marking Spoke Groups

See

Figure 2-44

. Mount wheel in WHEEL TRUING STAND

(Part No. HD-99500-80) using truing arbor. Tighten arbor
nuts so hub will turn on its bearings.

NOTE

The primary brake disc side of the hub has one or two grooves
cut into the disc mounting surface.

Lay a straightedge across the primary brake disc mounting
surface of hub and one of the marked spoke groups.

See

Figure 2-45

. Measure the distance from the

straightedge to the location shown, based on rim design,
to determine distance A. Refer to

Table 2-16

NOTES

•

Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the rim
to become out-of-round.

•

Tighten or loosen spokes one flat at a time and recheck
measurement.

•

Always work on groups that are opposite each other to
maintain radial runout.

If the dimension is not correct, adjust the four spokes using
SPOKE NIPPLE WRENCH (Part No. HD-94681-80). For
example: if the

right

side is

less

than specification,

loosen

the two spokes on the hub

right

side. Then

tighten

the

two spokes attached to the hub

left

side. Turn all four

spokes an equal number of turns until offset is to specific-
ation.

Repeat the previous step for all groups on the wheel. Verify
the offset.

True the wheel. See

2.7 CHECKING AND TRUING

WHEELS, Truing Laced Wheels

sm03223

Figure 2-44. Checking Wheel Hub Offset Dimension

(typical)

Table 2-16. Laced Wheel Hub Offset Dimensions

DIMENSION A

RIM

SIZE

NO.*

TYPE

37.39-37.90

1.472-1.492

Rear

28.94-29.55

1.139-1.163

Front

18.14-18.90

0.837-0.857

* See

Figure 2-45

sm07463a

1. 16 in rim, rear
2. 16 in rim, front
3. 21 in rim, front

Figure 2-45. Laced Wheel Hub Offset Dimensions

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2-34 2013 Sportster Service: Chassis

TRUING LACED WHEELS

TOOL NAME

PART NUMBER

SPOKE TORQUE WRENCH

HD-48985

SPOKE NIPPLE WRENCH

HD-94681-80

WHEEL TRUING STAND

HD-99500-80

TORQUE VALUE

FASTENER

6.2 Nm

in-lbs

Spoke nipple

NOTES

•

Dial indicators are more accurate than gauge rods.

•

Radial truing should be performed before lateral truing.

Radial Runout

See

Figure 2-46

. With the wheel mounted in WHEEL

TRUING STAND (Part No. HD-99500-80), adjust the truing
stand gauge (3) near to the rim's tire bead safety hump
(4). If using a dial indicator, place the tip on the safety
bead hump.

If working with a straight flange hub, seat each spoke head
in the hub flange using a flat nose punch and mallet.

NOTES

•

Always loosen the appropriate spokes, using SPOKE
NIPPLE WRENCH (Part No. HD-94681-80), before tight-
ening the other two. Reversing this procedure will cause
the rim to become out of round.

•

Tighten or loosen spoke, one flat at a time, and recheck
measurement. Small changes in the spokes can make
large changes in the runout.

•

Always work on groups that are opposite each other to
maintain radial runout.

Spin the rim slowly and check distance (2). The rim should
be true within 0.030 in (0.76 mm).

If the rim contacts the gauge on or near a marked
group of spokes, loosen the spokes in the group on
the opposite side of the rim. Then tighten the spokes
in the group where the rim makes contact an equal
number of turns.

If the rim contacts the gauge between two marked
groups, loosen the spokes in both groups on the
opposite side of the rim. Then tighten the spoke
groups on the side of the rim that makes contact an
equal number of turns.

When the wheel is centered and trued, start at the valve
stem hole and tighten any loose spoke nipples one turn
at a time until they are snug.

Working alternately across the wheel, use SPOKE
TORQUE WRENCH (Part No. HD-48985) evenly tighten
all spokes to specification listed in

Table 2-17

If working with a straight flange hub, verify each spoke
head is seated in the hub flange using a flat nose punch
and mallet.

Verify radial runout is still within specification.

After you have verified that radial runout is still within
specification, proceed to lateral runout.

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)

sm03117

1. Wheel truing and balancing stand
2. Radial runout
3. Gauge rod
4. Bead safety hump

Figure 2-46. Checking Radial Runout

Table 2-17. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

in-lbs

(6.2 Nm)

All

Lateral Runout

NOTE

Dial indicators are more accurate than gauge rods.

See

Figure 2-47

. With the wheel mounted in WHEEL

TRUING STAND (Part No. HD-99500-80), adjust the
gauge rod (3) near the rim bead flange.

Rotate the rim slowly and check lateral runout (2). If runout
exceeds 0.030 in (0.76 mm), adjust spokes as follows.

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2013 Sportster Service: Chassis 2-35

NOTES

•

Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the rim
to become out of round.

•

Tighten or loosen spoke, one flat at a time, and recheck
measurement. Small changes in the spokes can make
large changes in the runout.

Again working in groups of four, loosen two spokes on the
tight side and tighten the two spokes on the loose side.

Repeat with each group until wheel is within specification.

Verify all spoke nipples are tightened to the specification.
Refer to

Table 2-17

If the tire is removed from the rim, file or grind off ends of
spokes that protrude through the nipples to prevent
puncturing tube or rim seal when tire is mounted.

NOTE

After installation, verify the wheel is approximately centered
between the fork fender bosses.

sm03115

1. Wheel truing and balancing stand
2. Lateral runout
3. Gauge rod

Figure 2-47. Checking Lateral Runout

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2-36 2013 Sportster Service: Chassis

2.8

FRONT BRAKE MASTER CYLINDER

GENERAL

The front brake master cylinder designed for dual disc (two
caliper) operation has a larger bore than the master cylinder
designed for single disc (one caliper) operation.

See

Figure 2-48

. The bore size is cast into the side of the

master cylinder body facing the handlebar.

•

The single disc master cylinder has "11" (11 mm) cast into
the body.

•

The dual disc master cylinder has "1/2" (1/2 in) cast into
the body.

NOTE

Use only CCI #20 BRAKE GREASE to lubricate master cylinder
bores, pistons, primary cups and secondary cups. Use only
KS62F assembly grease on caliper pistons and piston seals.
Use only G40M BRAKE GREASE on the caliper pins and boots,
brake lever pivot hole, and the end of the piston that contacts
the brake lever.

Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)

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, IMMEDI-
ATELY flush area with clear water.

INSPECTION

Check the fluid level in the front brake reservoir. If it is low,
refill and bleed brake system. See

2.17 BLEEDING

BRAKES

Check for fluid leaks in the brake line, around banjo fittings
or front brake caliper pistons or bleeder valve. Repair and
bleed brake system.

For

brake

line

replacement

procedure,

see

2.16 BRAKE LINES

To repair front brake caliper, see procedure in

2.9 FRONT BRAKE CALIPER: XL MODELS

2.10 FRONT BRAKE CALIPER: XR 1200X

See

2.17 BLEEDING BRAKES

for hydraulic brake

system bleeding procedure.

Check front brake friction pads and disc(s) for excessive
wear or damage. Replace if necessary.

See

1.16 BRAKE PADS AND DISCS: XL MODELS

1.17 BRAKE PADS AND DISCS: XR 1200X

for

specifications and brake pad replacement procedure.

See

2.5 WHEELS

for brake disc replacement pro-

cedure.

Eliminate any air in the hydraulic brake assembly by
bleeding the system. See

2.17 BLEEDING BRAKES

If none of these conditions exist but the front brake system
does not operate properly, the front brake master cylinder is
defective. Repair or replace if necessary.

REMOVAL

See

Figure 2-49

. Loosen turn signal clamp screw (3) and

remove turn signal assembly (5) from front brake master
cylinder housing (1).

Remove locknut, washer (4) and mirror (2) from master
cylinder housing.

sm01237

Figure 2-48. Verifying Front Brake Master Cylinder Bore

Size (single disc master cylinder)

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2013 Sportster Service: Chassis 2-37

sm06942

1. Front brake master cylinder and reservoir
2. Mirror
3. Turn signal clamp screw
4. Locknut and washer
5. Turn signal assembly
6. Front brake banjo fitting
7. Banjo bolt
8. Sealing washer

Figure 2-49. Front Brake Master Cylinder (typical)

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)

See

Figure 2-50

and

Figure 2-51

. Drain brake fluid:

Remove bleeder nipple cap (2) from bleeder valve
(3) on front brake caliper (1).

Install a length of 5/16 in (7.9 mm) ID clear plastic
tubing over caliper bleeder valve (3). Place free end
in a suitable container.

Open bleeder valve about 1/2 turn.

Pump brake hand lever several times to drain brake
fluid.

Close bleeder valve.

NOTE

Dispose of brake fluid in accordance with local regulations.

sm01239

1. Front brake caliper
2. Bleeder nipple cap
3. Bleeder valve

Figure 2-50. Front Caliper Bleeder Valve (typical)

sm01424

Figure 2-51. Bleeding Hydraulic System

See

Figure 2-49

. Remove banjo bolt (7) and two washers

(8) to disconnect front brake line banjo fitting (6) from
master cylinder (1). Discard washers.

See

Figure 2-52

. Squeeze front brake lever and place a

5/32 in (4 mm) thick cardboard insert between brake lever
and lever bracket. Release brake lever.

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2-38 2013 Sportster Service: Chassis

sm01240

Figure 2-52. Install Cardboard Insert Before Removing

Master Cylinder Assembly

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

NOTE

Use the eyelet of an ordinary cable strap if the cardboard insert
is not available.

See

Figure 2-53

. Remove the two screws (6) and washers

(7) securing the handlebar clamp (8) to the master cylinder
housing (5). Remove the brake lever/master cylinder
assembly and clamp from the handlebar.

DISASSEMBLY

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

Figure 2-53

. Remove retaining ring (17) from pivot

pin (9) groove at bottom of master cylinder bracket. Dis-
card retaining ring.

Remove pivot pin and brake hand lever (18) from master
cylinder assembly.

Remove and discard dust boot (16).

NOTE

See

Figure 2-54

. Clamp front brake master cylinder in a vise

by the mirror mounting boss only. Use brass or aluminum jaw
covers or other protective device on vise jaws to prevent
damage to master cylinder.

See

Figure 2-54

. Clamp master cylinder in a vise so that

banjo fitting hole is pointing straight down.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 2-53

. Press down on end of piston and remove

retaining ring (15). Discard retaining ring.

Single disc piston assembly:

remove stop plate (22).

Remove and discard piston assembly (12, 13, 14) and
piston spring (11).

NOTES

•

See

Figure 2-53

. Both primary (12) and secondary (13)

cups are fitted into grooves in the piston body (14). The
piston spring (11) fits onto the end of the piston.

•

Always clean the cover before removal. This prevents dirt
and other contaminants from entering the master cylinder
reservoir.

Remove two screws (1), cover (2), diaphragm plate (3)
and diaphragm (4) from the master cylinder reservoir.

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2013 Sportster Service: Chassis 2-39

sm02388

13.

Secondary cup*

Screw (2)

14.

Reservoir cover

Piston*

15.

Retaining ring*

Diaphragm plate

16.

Diaphragm

Dust boot*

17.

Retaining ring

Master cylinder housing

18.

Screw (2)

Brake hand lever

19.

Bushing

Washer (2)

20.

Handlebar clamp

G40M brake grease*

21.

CCI #20 brake grease*

Pivot pin

10.

22.

Brake line banjo fitting seating surface

Stop plate (single disc piston only)*

23.

11.

Single disc piston assembly

Spring*

12.

24.

Primary cup*

Dual disc piston assembly

Figure 2-53. Front Brake Master Cylinder Assembly (*Provided in Service Parts Kit)

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2-40 2013 Sportster Service: Chassis

Harley Davidson 2013 Sportster Models. Service Manual - page 13