Harley Davidson 2013 Sportster Models. Service Manual - page 18

2-104 2013 Sportster Service: Chassis

sm06707

11.

Spring

Fork tube cap

12.

O-ring

Lower spring collar

13.

Outer tube

Slider ring

14.

O-ring

Slider bushing

15.

Guide bushing

Rod guide case

16.

Hex nut

Seal spacer

17.

Oil seal

Preload spring

18.

Rod piston assembly

Stopper ring

19.

Dust seal

Piston ring

10.

20.

Upper spring collar

Inner tube

Figure 2-151. Fork Assembly: XR 1200X

CLEANING AND INSPECTION

Thoroughly clean components.

Replace all oil seals and O-rings.

Inspect components. Replace as necessary.

Fork tube bushing and slider guide bushing for wear.

Dust cover (where it rubs on fork tube) for wear.

Springs for damaged coils.

Fork tube or slider for bends or wear.

2013 Sportster Service: Chassis 2-105

ASSEMBLY

TOOL NAME

PART NUMBER

FORK SEAL DRIVER AND DUST
BOOT INSTALLER

B-42571

OIL LEVEL GAUGE

B-59000B

FORK HOLDING TOOL

HD-41177

ROD CASE GUIDE SOCKET

HD-50083

FORK CAP WRENCH

HD-50084

TORQUE VALUE

FASTENER

26-30 Nm

19-22 ft-lbs

Fork piston rod hex nut: XR
1200X

90 Nm

66 ft-lbs

Rod guide case to inner tube:
XR 1200X

29-39 Nm

21-29 ft-lbs

Fork cap to outer tube: XR
1200X

Piston Rod Service

Separate the hex nut from the fork cap and remove the
fork cap and hex nut from the piston rod assembly.

NOTES

•

The piston rod assembly should not be disassembled any
further than is described.

•

Do not use TYPE "E" HYDRAULIC FORK OIL to lubricate
the components for assembly. Use BIG PISTON FORK
OIL.

See

Figure 2-152

. Replace the O-ring on the fork cap.

See

Figure 2-153

. Replace the rod guide case O-ring (1)

and the slider ring (2).

Replace the rebound spring.

See

Figure 2-154

. Replace the fork piston ring.

Install the hex nut and the fork cap on the piston rod
assembly.

Tighten to 19-22 ft-lbs (26-30 Nm).

sm06701

Figure 2-152. Fork Cap and O-Ring

sm06703

1. Rubber O-ring
2. Slider ring

Figure 2-153. Rod Guide Case and O-Rings

sm06702

Figure 2-154. Fork Rod Piston and Ring

Initial Assembly

See

Figure 2-155

. Install on the inner fork tube:

Dust seal (1)

Oil seal stopper ring (2)

Seal with the stamp side down (3)

Seal spacer with the chamfer up (4)

Guide bushing (6)

Slide bushing (5)

NOTE

Do not use TYPE "E" HYDRAULIC FORK OIL to lubricate the
components for assembly. Use BIG PISTON FORK OIL to
lubricate the components for assembly.

Spread fork oil or sealing grease inside the lip of the oil
seal.

Slide the inner tube into the outer tube.

2-106 2013 Sportster Service: Chassis

See

Figure 2-156

. Seat the oil seal with the FORK SEAL

DRIVER AND DUST BOOT INSTALLER (Part No. B-
42571).

Snap the stopper ring into the groove in the outer tube.

Seat the dust seal with the seal driver.

sm06698

1. Dust seal
2. Stopper ring
3. Oil seal
4. Spacer ring
5. Slide bushing
6. Guide bushing

Figure 2-155. Inner Tube Components

sm06699

Figure 2-156. Seating the Oil Seal

Fill with Fork Oil

Mount the fork assembly in the FORK HOLDING TOOL
(Part No. HD-41177) and fully compress the inner tube.

NOTE

Measure the fork spring. Replace as necessary. Refer to

Table 2-22

Install:

Lower spring collar

Fork spring

Upper spring collar

NOTE

Do not use TYPE "E" HYDRAULIC FORK OIL in the XR 1200X
forks.

Fill fork with BIG PISTON FORK OIL until the oil reaches
the side hole in the inner tube.

Pump the outer tube 8-10 times to expel the air from the
assembly.

NOTE

Do not damage the slide ring on the rod guide case.

Install the piston assembly:

Guide the piston rod into the inner tube.

Hand tighten the rod guide case to the inner tube.

Gently pull up on the outer tube to fit the slider ring
to the outer tube.

Using the ROD CASE GUIDE SOCKET (Part No. HD-
50083), tighten to 66 ft-lbs (90 Nm).

Fill fork with addition BIG PISTON FORK OIL until the oil
spills over the rod guide case.

Pump the piston assembly/outer tube several times to
expel any additional air.

2.10 FRONT BRAKE CALIPER: XR

2013 Sportster Service: Chassis 2-107

See

Figure 2-157

. Use the OIL LEVEL GAUGE (Part

No. B-59000B) to set the level of the oil in the outer fork
tube to specification. Refer to

Table 2-24

Table 2-22. Minimum Spring Service Length

MODEL

346.6

13.65

XR 1200X

Table 2-23. Fork Oil Volume

MODEL

580

19.6

XR 1200X

Table 2-24. Fork Oil Level

MODEL

1.77

XR 1200X

sm06700

Figure 2-157. Drawing Off Excess Fork Oil

Complete Assembly

Use the FORK CAP WRENCH (Part No. HD-50084) to
install the fork cap and tighten to 21-29 ft-lbs (29-39 Nm).

Adjust the preload to identical settings on both forks.

INSTALLATION

TOOL NAME

PART NUMBER

TRIPLE TREE WEDGE TOOL

HD-48287

TORQUE VALUE

FASTENER

40.7-47.5 Nm

30-35 ft-lbs

Fork, front, bracket pinch
screw

NOTES

•

Fork tube installation height must match the opposite side
exactly for proper vehicle operation, reliability and perform-
ance.

•

When installing fork leg in fork brackets, do not twist fork
leg to avoid damage to cosmetic finishes.

Identify left and right side fork assemblies.

Insert fork assembly from the lower fork bracket upward
through the upper fork bracket.

Remove TRIPLE TREE WEDGE TOOL (Part No. HD-
48287) used during removal process.

See

Figure 2-158

. Measure fork tube installation height.

Adjust fork tubes to specification. Refer to

Table 2-25

sm05356

Figure 2-158. Fork Installation Height Measurement

Table 2-25. Fork Installation Height Specifications

MODEL

9.86-11.88

0.388-0.468

XR 1200X

Tighten pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).

Install front fender and bracket. See

2.31 FRONT

FENDER

Install front brake caliper hydraulic lines and install front
brake calipers. See

1200X

Install front wheel and align the wheel to the forks. See

2.5 WHEELS

2.20 FRONT FORK: XR 1200X

2-108 2013 Sportster Service: Chassis

2.21

FORK STEM AND BRACKET ASSEMBLY

REMOVAL AND DISASSEMBLY

Cover the fuel tank.

Remove the fork assemblies. See

2.19 FRONT FORK:

XL MODELS

See

Figure 2-159

. Loosen fork stem pinch screw (7).

Remove fork stem bolt (9) and washer (8).

Lift handlebar assembly from steering head with fork upper
bracket (6) attached. Carefully position assembly out of
the way. Exercise caution to avoid damaging control
cables, wiring harnesses, clutch cable or brake lines.

NOTE

Only disconnect handlebar connections if removing as an
assembly.

Remove upper seal (5) and upper bearing cone (3). Slide
fork stem and lower bracket (1) from frame.

sm06711

1. Fork stem and lower bracket
2. Seal, lower
3. Bearing cone (2)
4. Bearing cup (2)
5. Seal, upper
6. Fork upper bracket
7. Fork stem pinch screw
8. Washer
9. Fork stem bolt
10. Pinch screw, upper (2)
11. Pinch screw, lower (2)
12. Steering head (part of frame)

Figure 2-159. Fork Stem and Bracket Assembly: Typical

2.20 FRONT FORK: XR 1200X

2013 Sportster Service: Chassis 2-109

CLEANING, INSPECTION AND REPAIR

TOOL NAME

PART NUMBER

UNIVERSAL DRIVER HANDLE

HD-33416

STEERING HEAD BEARING RACE
REMOVAL TOOL

HD-39301-A

See

Figure 2-159

. Clean the seals (2, 5), bearing cones

(3), fork stem and lower bracket (1) and steering head (12)
with solvent.

Inspect fork stem and lower bracket (1). Replace as
necessary.

NOTE

Replace bearings and bearing cups as a set.

Inspect bearings. Replace as necessary.

Pitting or scoring

Wear

Scoring

Turn the bearings in the races to check for roughness.
Replace as necessary.

Replace both bearing assemblies even if one assembly
appeares to be good. Mismatched bearings can lead to
excessive wear and premature replacement. (00532b)

Replace bearings and bearing cups as follows:

The lower bearing cone is a slip fit on the fork stem.
Remove lower bearing cone by sliding it up and off
fork stem. If necessary, gently pry bearing cone off
fork stem with a pair of flat blade screw drivers.
Remove lower seal (2).

Drive bearing cups from steering head using
STEERING HEAD BEARING RACE REMOVAL TOOL
(Part No. HD-39301-A) and UNIVERSAL DRIVER
HANDLE (Part No. HD-33416).

If bearing cups are

removed, the bearings cannot be reused. They
must be replaced.

ASSEMBLY AND INSTALLATION

TOOL NAME

PART NUMBER

STEERING HEAD BEARING RACE
INSTALLATION TOOL

HD-39302

TORQUE VALUE

FASTENER

31.2-36.6 Nm

23-27 ft-lbs

Fork, front, stem bolt, 1st
torque

8.1-10.9 Nm

72-96

in-lbs

Fork, front, stem bolt, final
torque

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch bolt

40.7-47.5 Nm

30-35 ft-lbs

Fork stem pinch bolt

See

Figure 2-159

. If bearing cups (4) were removed, obtain

new

bearings and bearing cups. Install

new

bearing cups

into frame steering head using STEERING HEAD
BEARING RACE INSTALLATION TOOL (Part No. HD-
39302).

Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)

Liberally coat the bearing cones (3) with SPECIAL PUR-
POSE GREASE. Work the grease thoroughly into the
bearing rollers.

Place lower bearing seal (2) over fork stem. Install lower
bearing cone (3) onto fork stem and bracket (1).

Insert fork stem and bracket (1) through the steering head.
Install bearing cone (3) and seal (5) onto the stem.

Install the upper bracket (6) including the handlebar
assembly and loosely install fork stem bolt (9) with washer
(8).

Install fork slider and tube assemblies. See

2.19 FRONT

FORK: XL MODELS

Leave both lower fork bracket pinch screws (11) loose.

Tighten fork stem bolt (9) to 23-27 ft-lbs (31.2-36.6 Nm).
Loosen fork stem bolt, then retighten to 72-96

in-lbs

(8.1-

10.9 Nm).

Tighten lower fork bracket pinch bolt to 30-35 ft-lbs (40.7-
47.5 Nm).

Tighten fork stem pinch screw (7) to 30-35 ft-lbs (40.7-
47.5 Nm).

10. Adjust

steering

head

bearing

fall-away.

See

1.19 STEERING HEAD BEARINGS, Fall-Away

2-110 2013 Sportster Service: Chassis

2.22

BELT GUARD AND DEBRIS DEFLECTOR

BELT GUARD: XL MODELS

TORQUE VALUE

FASTENER

13.6-20.4 Nm

120-180

in-lbs

Belt guard screw: XL Models

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

Removal

See

. Remove right side lower shock absorber

mount locknut (1).

Pull shock absorber mounting bolt (2) out slightly until it
clears mounting hole in belt guard (4).

Remove screw (5), washer (6) and nut (7) securing front
of belt guard to rear fork (10).

Installation

See

. Slide belt guard (4) into place. Tab on

front of belt guard mounts outboard of mounting bracket
on rear fork.

Secure front of belt guard to rear fork (10) with screw (5),
washer (6) and nut (7). Tighten to 120-180

in-lbs

(13.6-

20.4 Nm).

Push lower shock absorber bolt (2) through rear belt guard
mounting hole. Thread locknut (1) on screw. Tighten to
45-50 ft-lbs (61-68 Nm).

DEBRIS DEFLECTOR: XL MODELS

TORQUE VALUE

FASTENER

4.1-6.8 Nm

36-60

in-lbs

Debris deflector screw: XL
Models

Removal

See

. Loosen, but do not remove, three

screws with captive washers (9) securing debris deflector
(8) to underside of rear fork (10).

Slide debris deflector forward until keyway slots in deflector
clear screw heads.

Installation

See

. Position debris deflector (8) in place on

underside of rear fork (10).

Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots.

Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

sm01358a

1. Locknut
2. Mounting bolt
3. Washer
4. Belt guard
5. Screw
6. Washer
7. Nut
8. Debris deflector
9. Screw with captive washer (3)
10. Rear fork

Figure 2-160. Belt Guard/Debris Deflector: XL Models

BELT GUARD: XR 1200X

TORQUE VALUE

FASTENER

8.1-10.8 Nm

72-96

in-lbs

Belt guard screw: XR 1200X

Removal

See

. Remove two screws with captive washers

(2) securing belt guard to top of rear fork (5).

Installation

See

. Slide belt guard (1) into place on top

of rear fork (5).

Install two screws with captive washers (2).

Tighten to 72-96

in-lbs

(8.1-10.8 Nm).

2013 Sportster Service: Chassis 2-111

DEBRIS DEFLECTOR: XR 1200X

TORQUE VALUE

FASTENER

8.1-10.8 Nm

72-96

in-lbs

Debris deflector screw: XR
1200X

Removal

NOTE

Front screw is located inboard of debris deflector.

See

. Remove three screws with captive washers

(4) securing debris deflector (3) to underside of rear fork (5).

Installation

See

. Position debris deflector (3) in place on

underside of rear fork (5).

Install three screws (4).

Tighten to 72-96

in-lbs

(8.1-10.8 Nm).

sm04892

1. Belt guard
2. Screw with captive washer (2)
3. Debris deflector
4. Screw with captive washer (3) (front screw

inboard of debris deflector)

5. Rear fork

Figure 2-161. Belt Guard/Debris Deflector: XR 1200X

4.13 EXHAUST SYSTEM: XL MODELS

2-112 2013 Sportster Service: Chassis

2.23

REAR FORK

REMOVAL

NOTE

Label hardware for location and orientation upon removal.

Position motorcycle on a suitable lift.

XL models:

Remove rear exhaust pipe and muffler. See

XR 1200X:

Remove exhaust system. See

4.14 EXHAUST

SYSTEM: XR 1200X

Remove rear wheel. See

2.5 WHEELS

Remove rear brake caliper assembly from rear fork. See

2.14 REAR BRAKE CALIPER: XL MODELS

2.15 REAR

BRAKE CALIPER: XR 1200X

Remove screw(s) securing brake line clamp(s) to rear fork.

XR 1200X:

Remove fasteners securing brake line to left

side of rear fork.

Remove both shock absorber screws, washers and nuts
from rear fork. See

2.24 SHOCK ABSORBERS

Remove rear belt guard and debris deflector. See

2.22 BELT GUARD AND DEBRIS DEFLECTOR

10.

XL Models:

Remove rear brake reservoir cover by

grasping cover and gently pulling straight out from reser-
voir. Remove reservoir mounting screw and pull reservoir
back out of the way. See

2.13 REAR BRAKE MASTER

CYLINDER RESERVOIR

11.

XL Models:

Loosen, but do not remove, top mounting

screw from left passenger footrest bracket. Remove bottom
mounting screw. Move brake hoses and clamp forward
slightly to gain access to left rear fork/engine mount bolt.

12.

XR 1200X:

Remove left and right rider footrests. See

2.42 RIDER FOOT CONTROLS: XR 1200X

13. See

. Support rear fork (3). Remove rear

fork/engine mount bolts (1) and pull fork assembly from
frame.

sm01818

1. Bolt (2)
2. Bearing (2)
3. Rear fork
4. Pivot shaft
5. Frame
6. Retaining ring

Figure 2-162. Rear Fork Assembly

DISASSEMBLY

TOOL NAME

PART NUMBER

BEARING REMOVER/INSTALLER
TOOL

HD-46281

NOTE

See

Figure 2-162

. Remove pivot bearings (2) only if replace-

ment is required.

S e e

F i g u r e

2 - 1 6 3

U s i n g

B E A R I N G

REMOVER/INSTALLER TOOL (Part No. HD-46281) (4,
5, 6), carefully press bearing assemblies from fork bearing
bosses (2):

Place receiver cup (6) on press bed, with recessed
end of cup facing up.

Place rear fork pivot bearing boss (2) over cup as
shown in the photo.

Slide pilot (5) through bearing and into receiver cup.

Insert handle (4) through other rear fork pivot bearing
boss and bearing, down into pilot.

Engage press ram on end of handle and press
bearing out.

Turn rear fork over. Press out the opposite pivot bearing.

2013 Sportster Service: Chassis 2-113

sm01465

1. Rear fork
2. Pivot bearing boss
3. Press
4. Handle
5. Pilot
6. Receiver cup

Figure 2-163. Removing Rear Fork Pivot Bearings

CLEANING AND INSPECTION

Clean all components in solvent.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Blow dry with low pressure compressed air.

Carefully inspect bearings for wear and/or corrosion.
Replace as necessary.

See

. Make sure pivot bearing retaining ring

(6) is not bent or damaged. If it is, replace it with a

new

retaining ring.

Make sure retaining ring is fully seated in the groove in
each bearing (2).

Check that rear fork (3) is not bent, twisted or cracked.
Replace as necessary.

ASSEMBLY

TOOL NAME

PART NUMBER

BEARING REMOVER/INSTALLER
TOOL

HD-46281

See

. If necessary, press

new

bearings (2)

into

position

rear

fork,

using

BEARING

REMOVER/INSTALLER TOOL (Part No. HD-46281):

See

Figure 2-164

. Place receiver cup (7) on press

bed, with recessed end of cup facing up.

Place rear fork pivot bearing boss (2) over cup as
shown in the photo.

Place

new

pivot bearing (6) over pivot bearing boss,

with retaining ring side of bearing up.

Slide pilot (5) through

new

pivot bearing, through pivot

bearing boss, and into receiver cup.

Insert handle (4) down into pilot.

Engage press ram on end of handle and press
bearing down until retaining ring bottoms out in rear
fork pivot bearing boss.

Turn rear fork over. Press the other pivot bearing into rear
fork pivot bearing boss.

INSTALLATION

TORQUE VALUE

FASTENER

81.4-95.0 Nm

60-70 ft-lbs

Fork, rear, pivot/engine mount
bolt

61-68 Nm

45-50 ft-lbs

Footrest mount fastener

2.3-2.8 Nm

20-25

in-lbs

Brake master cylinder reser-
voir, rear, mounting screw

Slide rear fork assembly into position on motorcycle.

See

2.13 REAR BRAKE MASTER CYLINDER

. Holding rear fork assembly in position,

install rear fork/engine mount bolts (1). Tighten to 60-70
ft-lbs (81.4-95.0 Nm).

XL Models:

Position rear brake hose clamp and left pas-

senger footrest bracket in place. Install lower mounting
screw. Tighten both mounting screws to 45-50 ft-lbs (61-
68 Nm).

XL Models:

Install rear brake reservoir using screw with

captive washer. Tighten to 20-25

in-lbs

(2.3-2.8 Nm).

Place reservoir cover over reservoir and gently press cover
into place. See

RESERVOIR

XR 1200X:

Install left and right rider footrests. See

2.42 RIDER FOOT CONTROLS: XR 1200X

Install belt guard and debris deflector. See

2.22 BELT

GUARD AND DEBRIS DEFLECTOR

Install shock absorbers onto rear fork. See

2.24 SHOCK

ABSORBERS

4.13 EXHAUST SYSTEM: XL MODELS

2-114 2013 Sportster Service: Chassis

Install rear brake caliper assembly. See

2.14 REAR

BRAKE CALIPER: XL MODELS

2.15 REAR BRAKE

CALIPER: XR 1200X

XR 1200X:

Secure rear brake line to left side of fork. See

2.16 BRAKE LINES

10. Install rear wheel and adjust rear belt. See

2.5 WHEELS

11.

XL Models:

Install rear exhaust pipe and muffler. See

12.

XR 1200X:

Install exhaust system. See

4.14 EXHAUST

SYSTEM: XR 1200X

sm01466

1. Rear fork
2. Pivot bearing boss
3. Press
4. Handle
5. Pilot
6. Bearing
7. Receiver cup

Figure 2-164. Installing Rear Fork Pivot Bearings

GUARD: INDIA MODELS, Saree Guard: XL 883R, XL
1200C/C ANV (India)

2013 Sportster Service: Chassis 2-115

2.24

SHOCK ABSORBERS

REMOVAL

NOTES

•

If a lift is not available, remove and install one shock
absorber at at time.

•

If necessary to remove saree guards, see

2.36 SAREE

Note the shock absorber settings.

All Models:

Preload.

XR 1200X:

Rebound and compression.

See

Figure 2-165

. Remove fastener (1), washer (2) and

locknut (3) from bottom end of the shock absorber (4 or
5).

Remove the fastener (6) and washer (7 or 2) from top end
of shock absorber.

XL Models:

Remove the stud cover (8).

Remove the shock absorber.

CLEANING AND INSPECTION

NOTE

Replace shock absorbers as set if either unit is damaged.

Clean and inspect all parts for wear and damage.

Check rubber bushings for wear, cracking and stiffness.

Examine shock absorber for signs of leakage.

INSTALLATION

TORQUE VALUE

FASTENER

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

See

Figure 2-165

. Assemble the upper fastener stack.

XL Models:

Assemble the upper fastener (6), the

washer (7) and the stud cover (8).

XR 1200X:

Assemble the upper fastener (6) and the

washer (2).

Install shock absorber mounting stack through the shock
absorber (4 or 5).

Position bottom end of shock absorber against outboard
side of rear fork mount. Insert mounting bolt (1) and
washer (2) through the damper bushing (9) and the rear
fork mount.

Thread on the locknut (3).

Remove the upper mounting bolt and apply 2-3 drops of
LOCTITE 243 MEDIUM STRENGTH THREADLOCKER
AND SEALANT (blue) to the threads.

Install the mounting bolt into the frame boss. Tighten to
45-50 ft-lbs (61-68 Nm).

Tighten the lower shock absorber locknut to 45-50 ft-lbs
(61-68 Nm).

Adjust the shock absorber to the original settings.

All Models:

Preload.

XR 1200X:

Rebound and Compression.

sm01819C

1. Mounting bolt
2. Washer
3. Locknut
4. Shock absorber: XL models
5. Shock absorber: XR 1200X
6. Mounting bolt
7. Washer
8. Stud cover: XL models
9. Damper bushing

Figure 2-165. Shock Absorbers: All Models

2-116 2013 Sportster Service: Chassis

SHOCK DISPOSAL: SCHRADER VALVE
MODELS

Remove the shock.

See

Figure 2-166

. Locate the valve.

NOTE

Cap may require pliers to remove.

Remove the valve cap.

Discharging pressurized oil and gas can pierce skin and
cause flying debris, which could cause serious injury.
Wear safety glasses and gloves. (00601b)

Press the valve stem with a flat blade screwdriver to
release the gas.

Dispose of the shock.

sm06708

Figure 2-166. Schrader Valve Location: XR 1200X