Content .. 15 16 17 18 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 17

sm01464a

1. Front brake line
2. Lower fork bracket pinch bolt
3. Ruler

Figure 2-127. Measuring Front Brake Line Clearance

XL 1200V/CP/CB w/Mini-Ape

Fit the upper and lower clamps to the brake line grommets.

See

Figure 2-128

. Match the straight banjo bolt fitting to

the master cylinder and route the brake line over the top
of the mini-ape and behind the fork brackets.

Cross the brake line under the lower fork bracket and down
the fork leg to the brake caliper.

sm07196

1. Upper P-clamp
2. Lower P-clamp

Figure 2-128. Brake Line Routing: XL 1200V/CP/CB

w/Mini-Ape

XL 1200CP/CA with Drag Bar

See

Figure 2-129

. Fit the upper and lower clamps to the

brake line grommets.

Match the banjo bolt fitting to the master cylinder and route
the brake line behind the fork brackets.

Cross the brake line under the lower fork bracket and down
the fork leg to the brake caliper.

HOME

2013 Sportster Service: Chassis 2-89

sm07197

1. Upper P-clamp
2. Lower P-clamp

Figure 2-129. Brake Line Routing: XL 1200CP/CA w/Drag

Bar

XR 1200X

See

Figure 2-130

. Fit the upper clamp to the metal fitting

at the top of the single metal tube section.

NOTE

The brake line on dual disc models will self-align. It creates a
gap between the metal tubing section and the lower fork
bracket. Visually confirm the gap.

Route the brake line behind the handlebar and the fork
brackets.

Separate the two brake lines and route down to the cal-
ipers.

sm07202

Figure 2-130. Brakeline Routing: XR 1200X

REAR BRAKE LINE: XL MODELS

TORQUE VALUE

FASTENER

14.9-18.9 Nm

132-168

in-lbs

Stop lamp, rear, switch: XL
Models

8.14-13.6 Nm

72-120

in-lbs

Brake line/switch, rear, tee
bracket screw: XL Models

3.4-4.5 Nm

30-40

in-lbs

Brake hose clamp to battery
tray screw

3.4-4.5 Nm

30-40

in-lbs

Brake hose clamp to rear fork
screw

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

4.0-6.9 Nm

35-61

in-lbs

Brake caliper bleeder valve

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

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

HOME

2-90 2013 Sportster Service: Chassis

NOTE

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

Removal

Drain rear brake master cylinder reservoir. See

2.13 REAR

BRAKE MASTER CYLINDER RESERVOIR

Drain the rear brake line:

Remove bleeder nipple cap from bleeder valve on
rear brake caliper.

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

Open bleeder valve 1/2 turn.

Pump brake pedal to drain brake fluid.

Close bleeder valve.

See

Figure 2-131

. Unplug harness connectors [121] from

stop lamp switch (7).

Remove banjo bolt (2) and washers (1) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.

Remove screw (5) to detach brake line clamp (4) with
bushing (12) from rear fork.

Remove screw (10) to detach brake line clamp (9) from
battery tray bracket.

Remove screw (11) securing brake line/switch tee (6) to
battery tray bracket.

Feed brake line up through clamp (8).

Hold hex body of brake line/switch tee with an open-end
wrench. Remove stop lamp switch from brake line/switch
tee.

Installation

See

Figure 2-131

. Thread stop lamp switch (7) into brake

line/switch tee (6) on

new

rear brake line (3). Hold hex

body of brake line/switch tee with an open-end wrench.
Tighten stop lamp switch to 132-168

in-lbs

(14.9-18.9

Nm).

Feed rear brake line down through B-clamp (8).

Position brake line/switch tee mounting bracket on battery
tray bracket. Secure with screw (11). Tighten to 72-120

in-lbs

(8.14-13.6 Nm).

Install clamp (9) and screw (10) to secure rear brake hose
to battery tray bracket. Tighten screw to 30-40

in-lbs

(3.4-

4.5 Nm).

NOTE

When installing clamp (4), bushing (12) and screw (5), adjust
the brake hose length between rear caliper and clamp so there
is no extra length. Do not twist or stretch brake hose. Make
sure bushing sits squarely in clamp and around hose.

Install clamp (4) with bushing (12) and screw (5), to secure
rear brake hose to rear fork. Tighten screw to 30-40

in-lbs

(3.4-4.5 Nm).

NOTE

Master cylinder and brake caliper housings have a positive
stop for banjo fitting. When tightening banjo bolt into master
cylinder and brake caliper in the next step, rotate banjo fitting
clockwise until it contacts positive stop.

Position

new

washers (1) on each side of banjo fittings

by rear brake master cylinder and rear brake caliper. Insert
banjo bolts (2) through washers and banjo fittings. Tighten
to 20-25 ft-lbs (27.1-33.9 Nm).

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

NOTE

Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.

Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with DOT 4 BRAKE
FLUID and bleed brake system. See

2.17 BLEEDING

BRAKES

Tighten bleeder valve to 35-61

in-lbs

(4.0-6.9 Nm). Install

bleeder nipple cap.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Verify tail lamp, and stop lamp.

10. Test ride motorcycle. If rear brake feels spongy, bleed

system again. See

2.17 BLEEDING BRAKES

HOME

2013 Sportster Service: Chassis 2-91

sm01815

1. Washer (4)
2. Banjo bolt (2)
3. Rear brake line
4. Clamp
5. Screw
6. Brake line/switch tee
7. Stop lamp switch assembly
8. Clamp
9. Clamp
10. Screw
11. Screw
12. Bushing

Figure 2-131. Rear Brake Line: XL Models

REAR BRAKE LINE: XR 1200X

TORQUE VALUE

FASTENER

14.9-18.9 Nm

132-168

in-lbs

Stop lamp, rear, switch: XR
1200X

1.9-2.5 Nm

17-22

in-lbs

Brake line/switch, rear, tee
bracket screw: XR 1200X

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

4.0-6.9 Nm

35-61

in-lbs

Brake caliper bleeder valve

NOTE

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

Removal

Drain rear brake master cylinder reservoir. See

2.13 REAR

BRAKE MASTER CYLINDER RESERVOIR

Drain brake fluid:

Remove cap from bleeder valve on rear brake caliper.

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

Open bleeder valve 1/2 turn.

Pump brake pedal to drain brake fluid.

Close bleeder valve.

See

Figure 2-132

. Unplug harness connectors [121] from

stop lamp switch (2).

Remove banjo bolts (4) and washers (5) to detach rear
brake line (3) from master cylinder body and rear brake
caliper. Discard washers.

Remove fasteners (7) to detach brake line clamps (6) from
rear fork.

Remove fasteners (8) securing brake line bracket/switch
tee (1) to lower frame.

Hold hex body of brake line bracket/switch tee with an
open-end wrench. Remove stop lamp switch from brake
line bracket/switch tee assembly.

If necessary, remove clamp and bushing (9).

HOME

2-92 2013 Sportster Service: Chassis

sm05316

1. Brake line bracket/switch tee
2. Stop lamp switch assembly
3. Rear brake line
4. Banjo bolt (2)
5. Washer (4)
6. Clamp (2)
7. Fastener (2)
8. Fastener (2)
9. Clamp and bushing

Figure 2-132. Rear Brake Line: XR 1200X

Installation

See

Figure 2-132

. Thread stop lamp switch (2) into brake

line bracket/switch tee (1) on rear brake line (3). Hold hex
body of brake line bracket/switch tee with an open-end
wrench. Using a 1.0-in six-point deep socket, tighten stop
lamp switch assembly to 132-168

in-lbs

(14.9-18.9 Nm).

If removed, install clamp and bushing (9).

Do not bend metal brake line. Bending brake line could
cause metal fatigue and brake failure, which could result
in death or serious injury. (00543b)

Route brake line assembly to master cylinder and brake
caliper. Loosely install

new

washers (5) and banjo bolts

(4) to hold line in place.

Position brake line bracket/switch tee on lower frame and
secure with fasteners (8). Tighten to 17-22

in-lbs

(1.9-2.5

Nm).

Connect harness connectors [121] to stop lamp switch
(2).

NOTES

•

Make sure stop lamp switch harness does not contact
grounding strap.

•

Master cylinder and brake caliper housings have a positive
stop for banjo fitting. When tightening banjo bolt into
master cylinder and brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

With

new

washers (5) on each side of banjo fittings, tighten

banjo bolts (4) to 20-25 ft-lbs (27.1-33.9 Nm).

Secure brake line to bottom of rear fork with clamps (6)
and fasteners (7).

NOTE

Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.

Position motorcycle upright (not resting on jiffy stand). Fill
rear brake master cylinder reservoir with DOT 4 BRAKE
FLUID and bleed brake system. See

2.17 BLEEDING

BRAKES

Tighten bleeder valve to 35-61

in-lbs

(4.0-6.9 Nm). Install

bleeder nipple cap.

10. Verify tail lamp, and stop lamp.

11. Test ride motorcycle. If rear brake feels spongy, bleed

system again. See

2.17 BLEEDING BRAKES

HOME

2013 Sportster Service: Chassis 2-93

sm05017a

Figure 3-143. Oil Pump Cover Torque Sequence: XR 1200X

HOME

2013 Sportster Service: Engine 3-107

3.22

BOTTOM END OVERHAUL: ASSEMBLY

CRANKCASE

TOOL NAME

PART NUMBER

GEAR DETENT ASSEMBLY AID

B-45520

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

SPROCKET SHAFT SEAL/SPACER
INSTALLER

B-45676-A

CRANKSHAFT GUIDE TOOL

HD-42326-B

SPROCKET SHAFT ADAPTER

HD-42579-6

SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL

HD-42579-A

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-2

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586-A

TORQUE VALUE

FASTENER

4.3-5.4 Nm

38-48

in-lbs

Piston oil jet screw

4.3-5.4 Nm

38-48

in-lbs

Oil deflector plate screw: XR
1200X

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

13.6-27.1 Nm

120-240

in-lbs

Cylinder stud

Installing Piston Oil Jets

NOTES

•

Damaged gaskets will result in either oil leakage or low
oil pressure.

•

See

Figure 3-144

. Gasket (4) is part of piston oil jet (2)

assembly and is not sold separately.

See

Figure 3-144

. With oil jet pointed upward, install

new

piston oil jet assemblies (2) with gaskets (4) in right
crankcase.

Apply LOCTITE 222 LOW STRENGTH THREADLOCKER
AND SEALANT (purple) to TORX screws (3) and screws
(6).

Install TORX screws to secure piston oil jet assembly to
crankcase. Tighten to 38-48

in-lbs

(4.3-5.4 Nm).

XR 1200X:

Install oil deflector plate (5) using three screws

(6). Tighten to 38-48

in-lbs

(4.3-5.4 Nm).

sm01596a

1. Right crankcase
2. Piston oil jet (2)
3. Screw (4)
4. Gasket (2)
5. Oil deflector plate (XR 1200X)
6. Screw (3) (XR 1200X)

Figure 3-144. Piston Oil Jet Assemblies

Installing Pinion Shaft Bearings

See

Figure 3-145

. Lubricate pinion shaft and pinion shaft

bearing (2) with SCREAMIN' EAGLE ASSEMBLY LUBE.

Slip bearing on pinion shaft.

See

Figure 3-146

. Using TRANSMISSION SHAFT

RETAINING RING PLIERS (Part No. J-5586-A), install

new

retaining ring in groove of pinion shaft bearing inner

race. Make sure retaining ring is fully seated in groove.

HOME

3-108 2013 Sportster Service: Engine

sm03411a

1. Outer bearing race
2. Pinion shaft bearing
3. Retaining ring
4. Left main bearing
5. Retaining ring
6. Thrust washer
7. Left main oil seal
8. Retaining ring
9. Sprocket shaft spacer

Figure 3-145. Pinion Shaft and Left Main Bearings

sm06550

Figure 3-146. Installing Pinion Shaft Bearing and Retaining

Ring

Installing Left Main Bearing

NOTE

When installing the left main bearing, the bearing presses from
the inside of the left crankcase toward the outside. A shoulder

is incorporated into the left crankcase which allows the bearing
to be installed in one direction only.

See

Figure 3-147

. Using CRANKCASE BEARING

REMOVER/INSTALLER

(Part

No.

B-45655)

and

CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-2), press left main bearing into the
left crankcase.

Place support tube (1) on press bed with recessed
cup end facing up.

With the inboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.

Place left main bearing (4) over bearing bore. Insert
pilot/driver (5) through left main bearing, through
crankshaft bearing bore and into support tube.

Apply pressure with press ram (6) until left main
bearing bottoms out in bearing bore.

See

Figure 3-148

. Install

new

retaining ring from the inside

of the left crankcase.

sm01502a

1. Support tube (HD-42720-2)
2. Left crankcase
3. Crankshaft bearing bore
4. Left main bearing
5. Pilot/driver (B-45655)
6. Press ram

Figure 3-147. Installing Left Main Bearing in Crankcase

HOME

2013 Sportster Service: Engine 3-109

sm01503a

Figure 3-148. Installing Left Main Bearing Retaining Ring

Assembling Crankcase Halves

Install transmission assembly in left crankcase. See

5.14 TRANSMISSION INSTALLATION

NOTE

See

Figure 3-149

. The gear detent assembly Aid is used to

move the gear detent lever clear of the shifter drum for
assembly.

Retract detent assembly in right case half and install GEAR
DETENT ASSEMBLY AID (Part No. B-45520) until it bot-
toms in right case half.

Shift transmission to 1st gear.

Lubricate left main bearing with SCREAMIN' EAGLE
ASSEMBLY LUBE.

Assemble crankcase halves together.

See

Figure 3-150

. Install flywheel assembly in right

crankcase. Slide pinion shaft through outer race in
right crankcase.

Slide CRANKSHAFT GUIDE TOOL (Part No. HD-
42326-B) onto flywheel sprocket shaft.

Apply a thin coat of HARLEY-DAVIDSON HIGH-
PERFORMANCE SEALANT - GRAY to crankcase
joint faces.

See

Figure 3-151

. Carefully fit crankcases together.

NOTE

XR 1200X: See

Figure 3-152

. Install the double-ended

bolt in position 8 to secure the front cylinder head oil return
line.

Apply a drop of LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) to last few
threads of each crankcase fastener and install
fasteners (thirteen long and four short) in crankcase
assembly.

In sequence, tighten fasteners to 15-19 ft-lbs (20.3-
25.8 Nm).

Remove transmission gear detent assembly aid.

sm03417

1. Detent assembly
2. Detent assembly aid

Figure 3-149. Using Gear Detent Assembly Aid (Part No.

B-45520)

sm06549

Figure 3-150. Installing Flywheels in Right Crankcase

HOME

3-110 2013 Sportster Service: Engine

sm06554

Figure 3-151. Assembling Crankcases with Crankshaft

Guide Tool (Part No. HD-42326-B)

sm01380b

Figure 3-152. Crankcase Fastener Torque Sequence

See

Figure 3-153

and

Figure 3-154

. Install spacer in ID

new

seal. With the open (lipped) side of seal facing

outward, center seal/spacer assembly over bearing bore.

NOTES

•

Removing spacer after installation requires seal procedure
to be repeated.

•

The XR 1200X requires the use of the SPROCKET SHAFT
ADAPTER (Part No. HD-42579-6).

See

Figure 3-155

. Install bearing seal and spacer.

Center seal/spacer driver (2) over seal, so that the
sleeve (smaller O.D.) seats between seal wall and
garter spring.

Assemble SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL (Part No. HD-42579-A) (1)
and SPROCKET SHAFT SEAL/SPACER INSTALLER
(Part No. B-45676-A) onto sprocket shaft.

Rotate handle clockwise until the spacer makes con-
tact with the bearing. Remove tool from sprocket shaft.

Install retaining ring into groove in sprocket shaft bearing
bore.

sm06551

Figure 3-153. Open Side of Seal Faces Out

sm06553

Figure 3-154. Install Spacer and Seal

HOME

2013 Sportster Service: Engine 3-111

sm01509a

1. Bearing/seal installer (Part No. HD-42579-A)
2. Seal/spacer installer (Part No. B-45676-A)

Figure 3-155. Install Bearing Seal/Spacer

Installing Cylinder Base Studs

See

Figure 3-156

. If cylinder studs were removed, install them

as follows:

Pack clean towels into crankcase opening.

Place a steel ball into a head screw (1).

The cylinder studs (2) have a shoulder (3) at the lower
end. Place the end of the studs without the shoulder into
the head screw.

Install the studs in the crankcase with the shoulder end
down. Use an air gun (4) to drive the stud until the shoulder
reaches the crankcase.

Remove air gun. Use a torque wrench to tighten studs to
120-240

in-lbs

(13.6-27.1 Nm).

sm01510a

1. Head screw with ball inside
2. Cylinder stud
3. Shoulder on cylinder stud
4. Air gun

Figure 3-156. Cylinder Studs

CAM AND PINION GEAR IDENTIFICATION

NOTE

Prior to changing any cam gears, check gear shaft fit within
corresponding bushings. Worn bushings can cause excessive
backlash.

See

Figure 3-157

. Cam lobes are stamped with a number (1,

2, 3, or 4) followed by a letter. The number identifies the cam
location/function. The letter identifies the cam lobe profile. Refer
to

Table 3-42

sm03406

Figure 3-157. Cam Identification (typical)

HOME

3-112 2013 Sportster Service: Engine

Table 3-42. Cam Identification

CAM LOCATION

Rear exhaust

Rear intake

Front intake

Front exhaust

CAM GEARS AND GEARCASE COVER: XL
MODELS

TOOL NAME

PART NUMBER

CRANKSHAFT LOCKING TOOL

HD-43984

TORQUE VALUE

FASTENER

26-29 Nm

19-21 ft-lbs

Pinion shaft locking nut: XR
1200X

10.2-13.6 Nm

90-120

in-lbs

Gearcase cover fastener

See

Figure 3-158

. Make sure shaft key (1) is installed on

flywheel pinion shaft. Install oil pump drive gear (10) and
pinion gear (9) on pinion shaft.

NOTE

See

Figure 3-159

. Timing mark on pinion gear tooth is aligned

with keyway in ID of pinion gear. The timing mark will allow
you to easily position pinion gear over shaft key and against
oil pump drive gear on pinion shaft.

See

Figure 3-158

. Clean threads on pinion shaft and nut

(8). Apply several drops of LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red) to
threads of nut.

NOTE

When using CRANKSHAFT LOCKING TOOL, do NOT use
impact wrench to drive nut onto pinion shaft.

sm06924

1. Fastener
2. Cover
3. Gasket
4. Rear exhaust cam
5. Rear intake cam
6. Front intake cam
7. Front exhaust cam
8. Nut
9. Pinion gear
10. Oil pump drive gear
11. Shaft key

Figure 3-158. Gearcase Cover and Cam Gears

sm03418

1. Keyway
2. Timing mark at centerline of keyway

Figure 3-159. Pinion Gear Timing Mark and Keyway

HOME

2013 Sportster Service: Engine 3-113

sm03419

1. Pinion Gear
2. Shaft key
3. Oil pump drive gear
4. Pinion shaft

Figure 3-160. Oil Pump Drive Gear and Pinion Gear

Installed on Pinion Shaft

See

Figure 3-161

. Install pinion shaft nut.

Install CRANKSHAFT LOCKING TOOL (Part No. HD-
43984) over pinion shaft.

Install nut on pinion shaft.

Tighten to 19-21 ft-lbs (26-29 Nm).

Tighten an additional 15-19 degrees of rotation.

Remove CRANKSHAFT LOCKING TOOL (Part
No. HD-43984).

NOTE

See

Figure 3-162

. Install rear exhaust and front intake cam

gears before rear intake cam gear. This prevents an alignment
problem with the pinion gear.

Lubricate all cams and all cam bushings in right crankcase
with SCREAMIN' EAGLE ASSEMBLY LUBE.

See

Figure 3-162

. Rotate crankshaft until timing mark on

pinion gear points exactly at centerline of rear intake cam
bushing.

sm03420

Figure 3-161. Crankshaft Locking Tool (Part No. HD-43984)

See

Figure 3-158

. Install rear exhaust cam (4). Rotate

cam until timing mark (a slot) points exactly at centerline
of rear intake cam bushing.

Install front intake cam (6). Rotate cam until slotted timing
mark points exactly at centerline of rear intake cam
bushing.

NOTE

See

Figure 3-162

. "V" marks on rear intake cam are not used

for timing of Sportster model engines.

See

Figure 3-158

. Install rear intake cam (5). As you install

this cam, rotate it so that the three timing marks (dots) line
up exactly with timing marks on the pinion gear, rear
exhaust cam and front intake cam.

Install front exhaust cam (7). Rotate the cam to line up the
timing mark with the timing mark of the front intake cam.

10. See

Figure 3-162

. Verify timing marks. If necessary,

remove a cam, rotate it slightly, and install. If timing marks
are off even one tooth, engine will not run correctly.

11. See

Figure 3-158

. Install a

new

dry gasket (3) on gearcase

cover (2).

HOME

3-114 2013 Sportster Service: Engine

sm07124

1. Rear exhaust cam gear (1W)
2. Rear intake cam gear (2W)
3. Front intake cam gear (3W)
4. Front exhaust cam gear (4W)
5. Pinion gear

Figure 3-162. Cam, Pinion Gear and Timing Mark Indexing (cam #2 "V" marks are not used for timing)

12. Lubricate all cam bushings in gearcase cover with

SCREAMIN' EAGLE ASSEMBLY LUBE.

13. Install gearcase cover. Secure cover to crankcase with 11

fasteners.

14. See

Figure 3-163

. Tighten in sequence to 90-120

in-lbs

(10.2-13.6 Nm).

15. Gauge cam gear end play. See

3.17 BOTTOM END

OVERHAUL: DISASSEMBLY, Cam Gear End Play

sm01513a

Figure 3-163. Gearcase Cover Mounting Screw Torque

Sequence

CAM GEARS AND GEARCASE COVER: XR
1200X

TOOL NAME

PART NUMBER

CRANKSHAFT LOCKING TOOL

HD-43984

TORQUE VALUE

FASTENER

26-29 Nm

19-21 ft-lbs

Pinion shaft locking nut: XR
1200X

10.2-13.6 Nm

90-120

in-lbs

Gearcase cover fastener

10.2-13.6 Nm

90-120

in-lbs

Oil pump rotor cover screw:
XR 1200X

10.3-13.6 Nm

90-120

in-lbs

Check valve housing fastener:
XR 1200X

10.2-13.6 Nm

90-120

in-lbs

Gearcase cover fastener

See

Figure 3-164

. Make sure t-key (9) is installed on fly-

wheel pinion shaft. Install spacer (6) and pinion gear (5)
on pinion shaft.

NOTE

See

Figure 3-165

. Timing mark on pinion gear tooth is aligned

with keyway in ID of pinion gear. The timing mark will allow
you to easily position pinion gear over t-key and against oil
pump drive gear on pinion shaft.

See

Figure 3-164

. Clean threads on pinion shaft and nut

(4). Apply several drops of LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red) to
threads of nut.

HOME

2013 Sportster Service: Engine 3-115

sm05005a

1. Right crankcase half
2. Rear exhaust cam gear
3. Rear intake cam gear
4. Nut
5. Pinion gear
6. Spacer
7. Front intake cam gear
8. Front exhaust cam gear
9. T-key

Figure 3-164. Gearcase and Valve Train Components: XR

1200X

sm03418

1. Keyway
2. Timing mark at centerline of keyway

Figure 3-165. Pinion Gear Timing Mark and Keyway

NOTE

When using CRANKSHAFT LOCKING TOOL, do NOT use
impact wrench to drive nut onto pinion shaft.

See

Figure 3-166

. Install CRANKSHAFT LOCKING TOOL

(Part No. HD-43984) over pinion shaft. Install nut on pinion
shaft. Tighten to 19-21 ft-lbs (26-29 Nm). Then tighten nut
15-19 degrees of rotation. Remove CRANKSHAFT
LOCKING TOOL (Part No. HD-43984).

sm03420

Figure 3-166. Crankshaft Locking Tool (Part No. HD-43984)

NOTE

Because of the larger diameter gear on the outboard end of
the rear intake cam gear, install the rear exhaust and front
intake cam gears before the rear intake cam gear.

Lubricate all cams and all cam bores in right crankcase
with SCREAMIN' EAGLE ASSEMBLY LUBE.

See

Figure 3-167

. Rotate crankshaft until timing mark on

pinion gear points exactly at centerline of rear intake cam
bore.

Install rear exhaust cam. Rotate cam until timing mark (a
slot) points exactly at centerline of rear intake cam bore.

Install front intake cam. Rotate cam until slotted timing
mark points exactly at centerline of rear intake cam bore.

NOTE

V marks on rear intake cam are not used for timing of Sportster
model engines.

Install rear intake cam. Rotate the cam to line up the three
timing marks (dots) exactly with timing marks on the pinion
gear, rear exhaust cam and front intake cam.

Install front exhaust cam. Rotate the cam to line up its
timing mark (a dot) with timing mark (dot) of front intake
cam.

HOME

3-116 2013 Sportster Service: Engine

2.20

FRONT FORK: XR 1200X

REMOVAL

TOOL NAME

PART NUMBER

TRIPLE TREE WEDGE TOOL

HD-48287

Remove front brake calipers. See

2.10 FRONT BRAKE

CALIPER: XR 1200X

Remove front wheel assembly. See

2.5 WHEELS

Remove front fender and bracket assembly. See

2.31 FRONT FENDER

See

Figure 2-145

. Remove upper and lower fork bracket

pinch bolts.

Using TRIPLE TREE WEDGE TOOL (Part No. HD-48287),
insert wedge in fork brackets to relieve clamping pressure
on fork tubes.

Remove fork from upper and lower fork brackets.

Repeat steps for other side.

sm04451

Figure 2-145. Insert Triple Tree Wedge (typical)

DISASSEMBLY

TOOL NAME

PART NUMBER

FORK HOLDING TOOL

HD-41177

ROD CASE GUIDE SOCKET

HD-50083

FORK CAP WRENCH

HD-50084

Initial Disassembly

Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)

NOTE

Count and record the number of rotations out (counterclock-
wise) for the preload adjuster.

See

Figure 2-146

. Back the preload off the fork spring.

Clamp the outer tube in the FORK HOLDING TOOL (Part
No. HD-41177).

See

Figure 2-147

. Loosen the fork cap with the FORK

CAP WRENCH (Part No. HD-50084).

See

Figure 2-148