Harley Davidson 2013 Sportster Models. Service Manual

3.3

OIL PRESSURE

OPERATION

All Models

When an engine is cold, the engine oil is more viscous (thicker).
During start-up, oil pressure will be higher than normal and oil
circulation will be somewhat restricted. As the engine warms
to normal operating temperature, the engine oil warms up and
becomes less viscous. The oil pressure decreases.

•

Increased engine speed results in higher oil pressure. The
faster the oil pump rotors spin, the greater the volume of
circulated oil.

•

Decreased engine speed lowers the volume of oil pumped
and the measured oil pressure.

XL Models

The oil pump is non regulatory and delivers its entire volume
of oil under pressure to the oil filter mount.

XR 1200X

The feed oil pump incorporates a bypass valve that will open
at approximately 50 psi (345 kPa), preventing overpressure in
the oil cooler and related components. The XR 1200X incorpor-
ates a thermostat in the oil cooler return path.

Oil Pressure Indicator Lamp

See

Figure 3-1

. The oil pressure indicator lamp turns on to

indicate improper circulation of the engine oil.

Refer to

Table 3-20

. The oil pressure indicator lamp turns on

when:

•

Ignition switch is turned on prior to starting engine.

•

Oil is not circulating through the running engine.

•

Oil pressure is abnormally low on the running engine.

•

Engine is idling far below 1000 rpm.

The oil pressure indicator lamp turns off when oil is circulating
with adequate pressure through the engine running at 1000
rpm or greater.

sm02321

Figure 3-1. Oil Pressure Indicator Lamp

If the oil pressure indicator lamp remains lit, always check
the oil supply first. If the oil supply is normal and the lamp
is still lit, stop the engine at once and do not ride further
until the trouble is located and the necessary repairs are
made. Failure to do so may result in engine damage.
(00157a)

NOTE

Residual oil pressure in the filter housing will sometimes pre-
vent the lamp from turning on. This may occur when cycling
the ignition key to on after stopping the engine.

Table 3-20. Oil Lamp Troubleshooting

PROBABLE CAUSES

OIL PRESSURE INDICATOR LAMP

Empty oil tank.

Stays on at speeds above idle.

Clogged feed line (ice and sludge, freezing temperatures).

Air-bound oil line.

Grounded oil pressure switch wire.

Malfunctioning oil pressure switch.

Diluted oil.

Malfunctioning check valve. See

3.23 OIL FILTER MOUNT

and

3.12 PRECISION

COOLING SYSTEM: XR 1200X, Cylinder Head Oil Feed Assembly

Malfunctioning or improperly installed pressure relief valve.

Incorrect idle speed. Malfunctioning or improperly installed check valve. See

3.23 OIL

FILTER MOUNT

and

3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder

Head Oil Feed Assembly

Flickers at idle.

Malfunctioning or improperly installed pressure relief valve.

HOME

3-10 2013 Sportster Service: Engine

Table 3-20. Oil Lamp Troubleshooting

PROBABLE CAUSES

OIL PRESSURE INDICATOR LAMP

Malfunctioning signal switch.

Does not glow when ignition is turned on
(prior to operating engine).

Malfunction in wiring.

Burned-out signal bulb.

Dead battery.

See NOTE before this table.

CHECKING OIL PRESSURE

TOOL NAME

PART NUMBER

OIL PRESSURE SENDING UNIT
WRENCH

HD-41675

OIL PRESSURE GAUGE ADAPTER

HD-96921-125

OIL PRESSURE TEST GAUGE KIT

HD-96921-52D

OIL PRESSURE GAUGE ADAPTER

HD-96925-58

Fill oil tank to proper level. See

1.6 ENGINE OIL AND

FILTER

Slide a catch pan under the motorcycle.

Obtain OIL PRESSURE TEST GAUGE KIT (Part No. HD-
96921-52D).

Connecting Gauge: XL Models

See

Figure 3-2

. Detach wiring from oil pressure indicator

lamp switch (2).

Using OIL PRESSURE SENDING UNIT WRENCH (Part
No. HD-41675), remove oil pressure switch.

See

Figure 3-3

. Install OIL PRESSURE GAUGE

ADAPTER (Part No. HD-96925-58) (2) in oil pressure
indicator lamp switch mounting hole. Tighten adapter
snugly. DO NOT OVER-TIGHTEN.

Connecting Gauge: XR 1200X

See

Figure 3-5

. Disconnect the quick connect fitting from

the inlet side of the oil cooler (4). See

3.12 PRECISION

COOLING SYSTEM: XR 1200X, General

Connect OIL PRESSURE GAUGE ADAPTER (Part
No. HD-96921-125) (5) to the oil hose (6).

Connect the other end of the adapter to the oil cooler fitting
(4).

Testing Pressure

See

Figure 3-4

Figure 3-5

. Assemble banjo bolt (2),

washer (3), OIL PRESSURE GAUGE banjo fitting (1) and
second washer onto adapter and tighten snugly.

NOTE

For an accurate reading, engine oil should be at normal oper-
ating temperature: 230 °F (110 °C).

Temporarily secure oil pressure gauge and hose to
motorcycle frame with cable straps. Verify gauge and hose
assembly do not interfere with normal operation. Ride

motorcycle until engine reaches normal operating temper-
ature.

Check and record the pressure readings at normal idle
(approximately 1000 rpm) and again at 2500 rpm. Refer
to

Table 3-21

Table 3-21. Oil Pressure: At OperatingTemperature

XR 1200X**

XL MODELS*

rpm

kPa

psi

kPa

psi

110.3-137.9

16-20

43.3-82.7

7-12

1000

275.8-303.4

40-44

68.9-117

10-17

2500

* Pressure reading taken at oil pressure switch fitting.
** Pressure reading taken at oil cooler inlet.

Removing Gauge: XL Models

Stop engine. Remove OIL PRESSURE GAUGE assembly
from oil pressure indicator lamp switch mounting hole in
crankcase. Cut cable straps securing gauge and hose.
Remove banjo bolt, gauge assembly, washers and adapter
from vehicle.

See

Figure 3-2

. Coat threads of oil pressure switch (2)

with LOCTITE 565 PIPE SEALANT with TEFLON. Replace
the oil pressure switch. Using OIL PRESSURE SENDING
UNIT WRENCH, tighten switch snugly. DO NOT OVER-
TIGHTEN.

Plug in connector [120] (3) by pushing elbow connector
straight up onto stud on oil pressure switch.

Removing Gauge: XR 1200X

Stop engine. Cut cable straps securing gauge and hose.
Remove banjo bolt, gauge assembly, washers and adapter
from vehicle.

Connect oil hose to oil cooler fitting, making sure it is
securely latched.

Finalize Test

NOTE

If an appreciable amount of oil leaked out when oil pressure
switch was removed, replace with fresh oil.

Check oil level in oil tank. See

1.6 ENGINE OIL AND

FILTER

. Top off oil level if necessary.

Start engine. Test oil pressure switch for proper operation.
Check for oil leaks.

HOME

2013 Sportster Service: Engine 3-11

3.4

CRANKCASE BREATHING SYSTEM

XL MODELS

See

Figure 3-6

. On the piston downstroke, a mixture of crank-

case air and oil mist is vented up the pushrod covers (1)
through a breather valve (2) in each inner rocker box section.

The oil mist separates from the crankcase air, collects and
passes through a small drain hole adjacent to the exhaust valve
in the head where it eventually returns to the crankcase.

The crankcase air is routed through a passage in each cylinder
head. The crankcase air then travels through each air cleaner
backing plate mounting bolt (3) into the filtered side of the air
cleaner.

sm06838

1. Pushrod cover
2. Breather valve
3. Air cleaner backing plate bolt

Figure 3-6. Crankcase Breathing System: XL Models

XR 1200X

See

Figure 3-7

. During the piston downstroke, internal crank-

case pressure increases. Crankcase air/oil mist (9) is forced
into the area around the rocker arms and valve springs. The
vapor travels through two passages (6) in the inner rocker
cover. Then into a cavity (7) between the cylinder head and
inner rocker cover. The vapor then moves into the filter media
(8) of the breather valve (3).

The oil-laden vapor passes through the filter media (8) of the
breather valve assembly. The oil separates from the crankcase
air and drains back into cavity (7). There it flows toward the

exhaust valve. The oil then passes through a small drain hole
adjacent to the exhaust valve and returns to the crankcase.

Air pressure forces the breather umbrella valve (5) to open.
Air flows through a fitting (4) in the outer rocker cover. The
umbrella valve prevents the air from moving back into the
crankcase during piston upstroke. Air travels through a vapor
hose (2) connected to a hose and tee assembly (10) in the air
box. The air eventually exits into the intake air stream above
the induction module. The air is consumed by the engine.

sm06839

1. Rocker cover
2. Vapor hose
3. Breather valve assembly
4. Vapor hose fitting
5. Umbrella valve
6. Passage
7. Cavity
8. Filter media
9. Vapor from crankcase
10. Hose and tee

Figure 3-7. Crankcase Breathing System: XR 1200X

HOME

2013 Sportster Service: Engine 3-13

3.5

TROUBLESHOOTING

DIAGNOSING VALVE TRAIN NOISE

To diagnose and correct noisy hydraulic lifters and valve train
components, use the following procedures:

With engine and oil at normal operating temperature, check
oil pressure at 2000 rpm. If oil pressure is above 50 psi
(345 kPa) or below 5 psi (34 kPa), inspect oil pump,
crankcase passages and oil hoses. Repair or replace parts
as necessary.

If oil is reaching the hydraulic lifters, remove and inspect.
Clean lifter bore of all foreign material. Replace parts as
necessary. See

3.22 BOTTOM END OVERHAUL:

ASSEMBLY, Tappets

Examine pushrod, lifter and lifter bore for proper fit and
any signs of unusual wear. Replace parts as necessary.

Visually inspect camshaft lobes for abnormal wear.

Remove camshafts and pinion gear, clean and inspect for
wear and fit. Replace parts as necessary.

Remove cylinder head and rocker box assemblies. Check
rocker arm end play and check for binding. Inspect valve
stems for scuffing and check stem to guide clearance.
Check valve seats for signs of looseness or shifting.

Face valves and valve seats.

COMPRESSION TEST

TOOL NAME

PART NUMBER

CYLINDER COMPRESSION GAUGE

HD-33223-1

Combustion chamber leakage may cause performance issues.
A compression test can help determine the source of cylinder
leakage.

Test engine at normal operating temperature

Disconnect spark plug wires.

Clean around spark plug base. Remove spark plugs.

Connect CYLINDER COMPRESSION GAUGE (Part
No. HD-33223-1) to front cylinder.

Make sure transmission is in neutral. With throttle plate in
wide open position, crank engine continuously through 5-
7 full compression strokes.

Note gauge readings at the end of the first and last com-
pression strokes. Record test results.

Connect the gauge to the rear cylinder and repeat test.

Compression is normal if final readings are within
specification and do not indicate more than a 10 psi
(0.689 bar) variance between cylinders. Refer to

Table 3-22

Compression is below specification if the readings
are 100 psi (6.89 bar) for 883 cc engines or 150 psi
(10.3 bar) for 1200 cc engines. Refer to

Table 3-23

Inject approximately 1/2 oz (15 mL) SAE 30 engine oil into
each cylinder and repeat the compression tests on both
cylinders. Readings that are considerably higher during
the second test indicate worn piston rings.

NOTE

Verify throttle plate is in the closed position after testing.

Table 3-22. Normal Compression Ranges

COMPRESSION

ENGINE

bar

psi

11.4-12.4

165-180

XL 883

13.8-15.5

200-225

XL 1200

11.7-12.8

170-185

XR 1200X

Table 3-23. Compression Test Results

CAUSE

TEST RESULTS

Ring trouble

Compression low on first stroke, builds
up on the following strokes, but does not
reach normal. Improves when oil is
added to cylinder.

Valve trouble

Compression low on first stroke, does
not build up on following strokes. Does
not improve with the addition of oil.

Head gasket leak

Incorrect pushrod
length

CYLINDER LEAKAGE TEST

TOOL NAME

PART NUMBER

CYLINDER LEAKDOWN TESTER

HD-35667-A

The cylinder leakage test pinpoints engine problems including
leaking valves, worn, damaged or stuck piston rings and blown
head gaskets.

Use CYLINDER LEAKDOWN TESTER (Part No. HD-35667-
A). Follow the specific instructions supplied with the tester.

Run engine until it reaches normal operating temperature.

Clean around spark plug base. Remove spark plugs.

Remove the air cleaner and set the throttle in the wide
open position.

Rotate the piston to TDC of the compression stroke (both
valves closed).

To keep the crankshaft from turning when air pressure is
applied to the cylinder, engage transmission in fifth gear
and lock the rear brake.

NOTE

Before performing the cylinder leakage test, verify that the
tester itself is free from leakage. Apply a soap solution around
the tester fittings. Connect the cylinder leakdown tester to the
compressed air source. Look for any bubbles that would
indicate leakage from the tester.

HOME

3-14 2013 Sportster Service: Engine

Following the manufacturer's instructions, perform a cyl-
inder leakage test. Make a note of the percent of leakage.
Leakage greater than 12 percent indicates internal engine
problems.

Listen for air leaks at induction module intake, exhaust
pipe and head gasket.

Air escaping through the induction module indicates
a leaking intake valve.

Air escaping through the exhaust pipe indicates a
leaking exhaust valve.

NOTES

•

If air is escaping through valves, check pushrod length.

•

Complete the cylinder leakage test(s). Install the spark
plugs. Verify that the throttle plate is in the closed position
before starting the engine.

DIAGNOSING SMOKING ENGINE OR HIGH
OIL CONSUMPTION

Before removing the cylinder heads, check for compression
and cylinder leakage. See

3.5 TROUBLESHOOTING, Com-

pression Test

3.5 TROUBLESHOOTING, Cylinder Leakage

Test

Check Prior to Cylinder Head Removal

Oil tank overfilled.

Oil carryover.

Breather hose restricted.

Restricted oil filter.

Check After Cylinder Head Removal

Oil return passages for clogging.

Valve guide seals.

Valve guide to valve stem clearance.

Gasket surface of both head and cylinder.

Cylinder head casting's porosity allowing oil to drain into
combustion chamber.

O-ring damaged or missing from oil pump/crankcase
junction.

ADJUSTMENT AND TESTING

General

Often only cylinder head and cylinder repair is needed (valves,
rings, piston, etc.). Service these components with the engine
in the frame. See

3.13 TOP END OVERHAUL: DISASSEMBLY,

Stripping Motorcycle for Top End Repair

After disassembling the top end only, it may be found that
crankcase repair is necessary. Crankcase repair requires
removal

engine

crankcase

from

chassis.

See

3.10 REMOVING ENGINE FROM CHASSIS

NOTE

Do not lay engine on primary side. Laying engine on primary
side will damage the clutch cable end fitting. If fitting is dam-
aged, replace the clutch cable.

Symptoms indicating a need for engine repair are often mis-
leading. If more than one symptom is present, possible causes
can be narrowed down to make a partial diagnosis. An above-
normal consumption of oil, for example, could be caused by
several mechanical faults. However, when accompanied by
blue-gray exhaust smoke and low engine compression, it
indicates worn piston rings. Low compression by itself however,
may indicate leaking valves, in addition to worn piston rings.
See

1.28 TROUBLESHOOTING

Piston slap is a condition where piston and/or cylinder are worn
out-of-round and are loose fitting, allowing the piston to slap
from front to rear of the cylinder as it moves up and down.

Frequently, valves, rings, pins, bushings and bearings need
attention at the same time. If any one of the above components
is worn, inspect all of these components. Repair or replace as
necessary.

HOME

2013 Sportster Service: Engine 3-15

3.6

ENGINE LUBRICATION SYSTEM

OIL PUMP OPERATION

The oil pump consists of two gerotor gear sets housed in one
pump body. One is feed and the other scavenge (return). Each
gerotor gear set has an inner and an outer gerotor. The inner
gerotor has one less lobe than the outer gerotor. Both gerotors
have fixed centers which are offset to each other. The inlet and
outlet sides of the pump are sealed by the tips and lobes of
the gerotor set. This prevents oil on the outlet side (high pres-
sure) from being transferred to the inlet side.

The feed pump distributes oil to the engine and has fewer lobes
than the scavenge pump, allowing for greater pressure devel-
opment. The scavenge pump returns oil to the tank and has
more lobes than the feed pump allowing for greater oil flow.

XL Models:

See

Figure 3-8

. Both rotor sets (3, 4) are driven

off a common shaft (2) that is coupled by gears to the crank-
shaft.

XR 1200X:

See

Figure 3-9

. The feed rotor set (4) is driven by

flats on the front intake camshaft (3). The scavenge rotor set
(5) is driven by flats on the rear exhaust camshaft (2).

sm06837

1. Body
2. Gear shaft
3. Scavenge rotor set
4. Feed rotor set
5. Cover

Figure 3-8. Oil Pump: XL Models

HOME

3-16 2013 Sportster Service: Engine

4.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

4.5 FUEL TANK: XR 1200X, Installing Fuel Tank

4.1-6.7 Nm

36-60

in-lbs

Air box to bracket fasteners: XR 1200X

4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V

9.5-13.6 Nm

84-120

in-lbs

Air cleaner breather screw

4.3 AIR CLEANER ASSEMBLY, XL 1200V

9.5-13.6 Nm

84-120

in-lbs

Air cleaner breather screw

4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

4.3 AIR CLEANER ASSEMBLY, XL 1200V

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

4.3 AIR CLEANER ASSEMBLY, XL Models except
XL 1200V

4.5-6.8 Nm

40-60

in-lbs

Air filter screw

4.3 AIR CLEANER ASSEMBLY, XL 1200V

4.5-6.8 Nm

40-60

in-lbs

Air filter screw

4.13 EXHAUST SYSTEM: XL MODELS, Installation

13.6-20.4 Nm

120-180

in-lbs

Brake rod to bell crank screw

4.13 EXHAUST SYSTEM: XL MODELS, Installation

10.9-13.6 Nm

96-120

in-lbs

Cylinder head exhaust port nut

4.9 INDUCTION MODULE: XR 1200X, Installation

29.8-35.3 Nm

22-26 ft-lbs

Cylinder head oil feed flare fitting: XR
1200X

4.9 INDUCTION MODULE: XR 1200X, Installation

17.6-23.0 Nm

13-17 ft-lbs

Cylinder head oil feed line flare nut: XR
1200X

4.7 ENGINE TEMPERATURE (ET)
SENSOR, Installation

13.6-19.0 Nm

120-168

in-lbs

ET sensor

4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister

4.1-6.8 Nm

36-60

in-lbs

EVAP canister clip mounting screw

4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister

4.0-5.1 Nm

35-45

in-lbs

EVAP canister guard screw

4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting bracket screw

4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister

23.1-29.9 Nm

17-22 ft-lbs

EVAP canister mounting bracket screw

4.14 EXHAUST SYSTEM: XR 1200X, Installation

40.7-44.7 Nm

30-33 ft-lbs

Exhaust clamp, lower nut: XR 1200X

4.14 EXHAUST SYSTEM: XR 1200X, Installa-
tion/SPECIAL SEQUENCE TO TIGHTEN

10.8-13.6 Nm

96-120

in-lbs

Exhaust flange nut: XR 1200X

4.13 EXHAUST SYSTEM: XL MODELS, Installation

2.3-4.5 Nm

20-40

in-lbs

Exhaust heat shield clamps

4.14 EXHAUST SYSTEM: XR 1200X, Installation

2.3-4.5 Nm

20-40

in-lbs

Exhaust heat shield clamps

4.13 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket screw: XL
Models

4.13 EXHAUST SYSTEM: XL MODELS, Installation

27.1-40.7 Nm

20-30 ft-lbs

Exhaust pipe clamp nut: XL Models

4.5 FUEL TANK: XR 1200X, Assemble Fuel Tank

4.5-5.1 Nm

40-45

in-lbs

Filler housing screws

4.15 FUEL INJECTORS, Installation

6.8 Nm

in-lbs

Fuel hose retaining bracket screw

4.16 FUEL PUMP, Assembly

2.1-4.1 Nm

19-36

in-lbs

Fuel pump bracket mounting screw

4.16 FUEL PUMP, Installation

4.5-5.1 Nm

40-45

in-lbs

Fuel pump module mounting screw

4.17 FUEL FILTER ELEMENT, Installation

4.5-5.1 Nm

40-45

in-lbs

Fuel pump module mounting screw

4.5 FUEL TANK: XR 1200X, Installing Fuel Tank

2.7-3.4 Nm

24-30

in-lbs

Fuel tank cover screw: XR 1200X

4.5 FUEL TANK: XR 1200X, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fastener: XR 1200X

4.5 FUEL TANK: XR 1200X, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fastener: XR 1200X

HOME

2013 Sportster Service: Fuel System 4-1

NOTES

TORQUE VALUE

FASTENER

4.4 FUEL TANK: XL MODELS, Installing Fuel Tank

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL Models

4.8 INDUCTION MODULE: XL MODELS, Installa-
tion

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL Models

4.15 FUEL INJECTORS, Installation

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL Models

4.10 IDLE AIR CONTROL (IAC), Installation: XL
Models

6.8 Nm

in-lbs

IAC mounting screw: XL models

4.8 INDUCTION MODULE: XL MODELS, Assembly

6.8 Nm

in-lbs

IAC mounting screw: XL Models

4.9 INDUCTION MODULE: XR 1200X, Assembly

6.8 Nm

in-lbs

IAC mounting screw: XR 1200X

4.10 IDLE AIR CONTROL (IAC), Installation: XR
1200X

6.8 Nm

in-lbs

IAC mounting screw: XR 1200X

4.8 INDUCTION MODULE: XL MODELS, Assembly

6.8 Nm

in-lbs

Induction module cable bracket screw:
XL Models

4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover to cylinder head
fastener: XR 1200X

4.9 INDUCTION MODULE: XR 1200X, Installation

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover to cylinder head
sockethead bolts: XR 1200X

4.9 INDUCTION MODULE: XR 1200X, Installation

10.2-13.6 Nm

90-120

in-lbs

Induction module cover to induction
module fastener: XR 1200X

4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Induction module cover to induction
module fastener: XR 1200X

4.9 INDUCTION MODULE: XR 1200X, Installation

10.2-13.6 Nm

90-120

in-lbs

Induction module cover to wire form
fastener: XR 1200X

4.8 INDUCTION MODULE: XL MODELS, Installa-
tion

10.2-13.6 Nm

90-120

in-lbs

Induction module mounting bracket
screw: XL models

4.8 INDUCTION MODULE: XL MODELS, Assembly

4.0 Nm

in-lbs

Induction module screw: XL models

4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XL
Models

4.0 Nm

in-lbs

Induction module screw: XL Models

4.8 INDUCTION MODULE: XL MODELS, Installa-
tion

10.9-13.6 Nm

96-120

in-lbs

Intake manifold mounting screw: XL
models

4.9 INDUCTION MODULE: XR 1200X, Installation

10.3-13.6 Nm

90-120

in-lbs

Intake manifold mounting screw: XR
1200X

4.14 EXHAUST SYSTEM: XR 1200X, Installation

40.7-44.7 Nm

30-33 ft-lbs

Interconnect bracket to frame fastener:
XR 1200X

4.20 EVAPORATIVE EMISSIONS CONTROL, Char-
coal Canister

23.0-29.8 Nm

17-22 ft-lbs

Master cylinder mounting bracket, rear,
screw: XL models

4.13 EXHAUST SYSTEM: XL MODELS, Installation

40.7-44.7 Nm

30-33 ft-lbs

Muffler interconnect bracket mounting
screw: XL Models

4.14 EXHAUST SYSTEM: XR 1200X, Installation

61.0-67.8 Nm

45-50 ft-lbs

Muffler mount to frame, front fastener:
XR 1200X

4.14 EXHAUST SYSTEM: XR 1200X, Installation

20.3-27.1 Nm

15-20 ft-lbs

Muffler mount to frame, rear fastener:
XR 1200X

4.14 EXHAUST SYSTEM: XR 1200X, Installation

13.6-20.3 Nm

120-180

in-lbs

Muffler to front muffler mount fastener:
XR 1200X

4.13 EXHAUST SYSTEM: XL MODELS, Installation

20.4-25.8 Nm

15-19 ft-lbs

Muffler to interconnect bracket screw:
XL Models

4.14 EXHAUST SYSTEM: XR 1200X, Installation

13.6-20.3 Nm

120-180

in-lbs

Muffler to muffler bolt: XR 1200X

4.13 EXHAUST SYSTEM: XL MODELS, Installation

51.6-58.4 Nm

38-43 ft-lbs

Muffler torca clamp nut

HOME

4-2 2013 Sportster Service: Fuel System

NOTES

TORQUE VALUE

FASTENER

4.14 EXHAUST SYSTEM: XR 1200X, Installation

13.6-20.3 Nm

120-180

in-lbs

Muffler to rear muffler mount fastener:
XR 1200X

4.12 OXYGEN (O2) SENSOR, Installation

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

4.13 EXHAUST SYSTEM: XL MODELS, Installation

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

4.13 EXHAUST SYSTEM: XL MODELS, Installation

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and lower
screws

4.9 INDUCTION MODULE: XR 1200X, Assembly

6.8 Nm

in-lbs

Throttle cable bracket screw: XR 1200X

4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X

9.0 Nm

in-lbs

TMAP sensor screw

4.6 THROTTLE POSITION SENSOR
(TPS), Installation: XL Models

4.0 Nm

in-lbs

TPS screw: XL Models

4.6 THROTTLE POSITION SENSOR
(TPS), Installation: XR 1200X

3.3 Nm

in-lbs

TPS screw: XR 1200X

4.11 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Wire form to induction module cover
fastener: XR 1200X

HOME

2013 Sportster Service: Fuel System 4-3

4.2

SPECIFICATIONS: FUEL SYSTEM

SPECIFICATIONS

Table 4-1. 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 4-2. 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

HOME

4-4 2013 Sportster Service: Fuel System

4.3

AIR CLEANER ASSEMBLY

XL MODELS EXCEPT XL 1200V

TORQUE VALUE

FASTENER

9.5-13.6 Nm

84-120

in-lbs

Air cleaner breather screw

4.5-6.8 Nm

40-60

in-lbs

Air filter screw

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

Removal

See

Figure 4-1

. Remove two screws (1) and trim insert

(2) from air cleaner cover (3).

Remove air cleaner cover from air cleaner backplate (10).

Remove air cleaner seal (4) from air cleaner cover.

Remove three screws (5). Remove air filter element (6)
and gasket (7). Discard gasket.

Remove O-rings from the breather screws (9). Discard
the O-rings.

Install air filter before running engine. Failure to do so can
draw debris into the engine and could result in engine
damage. (00207a)

Remove two breather screws (9) from air cleaner back-
plate.

Remove air cleaner backplate and gasket (11).

Installation

See

Figure 4-1

. Position

new

gasket (11) and air cleaner

backplate (10) at induction module air inlet.

Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to existing screws or use

new

breather screws (9). Install air cleaner backplate to

engine heads. Tighten to 84-120

in-lbs

(9.5-13.6 Nm).

To prevent damage, apply a thin coat of engine oil to O-
rings (8). Install O-rings to breather tubes.

Position

new

gasket (7) on air cleaner backplate. Line up

gasket holes with backplate holes.

Install air filter element (6) onto backplate. Secure with
three

new

screws (5) or apply LOCTITE 243 MEDIUM

STRENGTH THREADLOCKER AND SEALANT (blue) to
existing screws. Tighten to 40-60

in-lbs

(4.5-6.8 Nm).

Install air cleaner seal (4) on air cleaner cover (3). Fit the
air cleaner seal around the entire edge of cover.

Install air cleaner cover onto backplate. Do not pinch or
distort seal.

Install trim insert (2) and air cleaner cover with two screws
(1). Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

sm06706a

1. Screw (2)
2. Trim insert
3. Cover
4. Seal
5. Screw (3)
6. Filter element (includes item 7)
7. Filter element gasket
8. O-ring (2)
9. Breather screw (2)
10. Backplate
11. Gasket

Figure 4-1. Air Cleaner Assembly: All XL except XL 1200V

XL 1200V

TORQUE VALUE

FASTENER

9.5-13.6 Nm

84-120

in-lbs

Air cleaner breather screw

4.5-6.8 Nm

40-60

in-lbs

Air filter screw

4.1-6.8 Nm

36-60

in-lbs

Air cleaner cover screw

Removal

See

Figure 4-2

. Remove the cover screw (1).

Remove the cover (2) and the seal (3).

Remove the three screws (4), the air filter element (5) and
gasket (9).

Remove the O-rings (10). Discard the O-rings.

Remove the two breather screws (6).

Remove the backplate (7) and gasket (8).

Inspect and replace parts as necessary.

Clean or replace the air filter element as necessary. See

1.7 AIR FILTER, Cleaning Filter Element

HOME

2013 Sportster Service: Fuel System 4-5

Installation

See

Figure 4-2

. Install the gasket (8) and backplate (7).

Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to existing screws or use

new

breather screws (6). Install the breather screws.

Tighten to 84-120

in-lbs

(9.5-13.6 Nm).

Apply engine oil to

new

O-rings (10). Install the O-rings

on the breather tubes.

Install the filter gasket (9).

Install the air filter element (5) and screws (4). Tighten to
40-60

in-lbs

(4.5-6.8 Nm).

Fit the cover (2) to the seal (3).

Install the cover and screw (1). Tighten to 36-60

in-lbs

(4.1-6.8 Nm).

sm07431

1. Screw
2. Cover
3. Seal
4. Screw (3)
5. Filter element
6. Breather screw
7. Backplate
8. Backplate gasket
9. Filter gasket
10. O-ring

Figure 4-2. Air Cleaner Assembly: XL 1200V

XR 1200X

Removal

Remove the fuel tank. See

4.5 FUEL TANK: XR 1200X

HDI Models:

Disconnect active intake solenoid connector

[178].

NOTE

Leave the rubber coupling attached to the induction module.

Lift the air box off induction module.

See

Figure 4-3

. Disconnect the crankcase breather hoses

from the front and rear rocker cover fittings.

Remove the air box assembly.

Remove the cover and air filter element as necessary.
See

1.7 AIR FILTER, XR 1200X

Replace damaged parts as necessary.

sm07432

1. Breather hose
2. Clamp
3. Breather hose assembly
4. Coupling

Figure 4-3. Air Box: XR 1200X

Installation

NOTE

See

Figure 4-4

. Check that the breather hose assembly (4)

inside the air box does not interfere with the active air solenoid
flapper.

Install all hoses.

Snap the anchor barb (1) of the front crankcase vent hose
in the hole (2) in the air box bottom.

If removed, install the air filter element and cover. See

1.7 AIR FILTER, XR 1200X

Seat the rubber coupling on the induction module.

Verify that the clamps are in place.

See

Figure 4-5

. Hold the air box close. Connect crankcase

vent hoses to the fittings (2) on the front and rear rocker
covers.

NOTE

The edge of hole in air box must encircle the groove in the
coupling.

HOME

4-6 2013 Sportster Service: Fuel System

4.4

FUEL TANK: XL MODELS

PURGING AND DISCONNECTING FUEL
SUPPLY HOSE

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Purge the fuel supply line of high pressure gasoline.

Remove left side cover. See

2.18 LEFT SIDE COVER

See

Figure 4-6

. Remove fuel pump connector from

ECM caddy cover (2).

Unplug fuel pump connector [141].

Start engine and allow vehicle to run.

When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.

Shut off ignition.

See

Figure 4-7

. Push up on release sleeve (1) on fuel

pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3) from fuel
pump module (4). Immediately clean up any fuel spills.

sm06566

1. Fuel pump wiring
2. ECM caddy cover (fuel pump connector inside)

Figure 4-6. Fuel Pump Connector: XL Models

sm01546c

1. Release sleeve (quick-connect fitting)
2. Fuel supply hose fitting
3. Fuel supply hose
4. Fuel pump module

Figure 4-7. Fuel Tank Quick-Connect Fitting

REMOVING FUEL TANK

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse.

Remove seat.

NOTES

•

If the fuel tank is being removed only to gain access to
items otherwise hidden, it is not necessary to drain the
fuel from the tank. If the fuel tank is to be disassembled
or repaired, follow the step below to drain the fuel.

•

Drain fuel into an approved container.

Drain fuel tank:

Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.

Position vehicle upright. Remove fuel tank filler cap.

Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.

Direct the pump output into an approved container.

Pump fuel until fuel tank is empty.

Immediately wipe up any spilled fuel.

See

Figure 4-8

. Remove vent hose (1) from fuel tank vent

nipple. Remove cable clip (3) securing fuel pump wiring
harness (2) to mounting boss on H-bracket.

Unplug fuel pump connector [141].

HOME

4-8 2013 Sportster Service: Fuel System

Remove protective caps, locknuts, screws and washers
from front and rear of fuel tank.

Place a clean, soft cloth over front of fuel tank to keep tank
from contacting top fork clamp and damaging paint. Lift
up rear of fuel tank. Remove fuel pump harness from clip
on wire harness caddy latch clip on frame backbone.

Lift fuel tank off motorcycle.

Remove fuel pump assembly. See

4.16 FUEL PUMP

sm06594c

1. Vent hose
2. Fuel pump wiring harness
3. Cable clip

Figure 4-8. Fuel Tank Vent Hose

CLEANING AND INSPECTION

Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.

Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.

Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.

Inspect the fuel tank for leaks or other damage. If a dam-
aged fuel tank cannot be successfully repaired, replace
it.

INSTALLING FUEL TANK

TORQUE VALUE

FASTENER

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL
Models

NOTE

Verify wiring harnesses are not pinched between fuel tank and
frame during tank installation.

Install fuel pump into fuel tank using

new

gasket. See

4.16 FUEL PUMP

See

Figure 4-9

. Position fuel tank on motorcycle. Verify

that front fuel tank brackets are located outboard of ignition
coil bracket (8).

Install front fastener.

Place washer (4) on long screw (2).

From right to left, push screw through front fuel tank
bracket, ignition coil bracket and frame.

Place second washer over screw.

Hand-start locknut (5).

x0671a4x

1. Fuel tank (typical)
2. Screw (long)
3. Screw (short)
4. Washer (4)
5. Locknut (2)
6. Protective cap (2)
7. Cosmetic cover (2)
8. Ignition coil bracket

Figure 4-9. Fuel Tank Mounting (typical)

See

Figure 4-10

. Place a clean, soft cloth over front of fuel

tank to keep tank from contacting top fork clamp and
damaging paint.

Lift up rear of fuel tank.

Place fuel pump wiring harness (1) into clip on wire har-
ness caddy latch clip on frame backbone tube. Verify that

HOME

2013 Sportster Service: Fuel System 4-9

the harness forms a loop (5) between caddy latch clip and
fuel pump module (6). Do not pinch harness between fuel
tank and frame backbone tube.

Route fuel pump wiring harness down along left side of
H-bracket. Secure with cable clip (3). Push clip into hole
in mounting boss (2) on H-bracket.

Install fuel tank.

Lower rear of fuel tank into position.

See

Figure 4-9

. Place washer (4) on short screw (3).

From right to left, push screw through rear fuel tank
bracket and frame.

Place second washer over screw

Hand-start locknut (5).

Tighten both front and rear fuel tank mounting
fasteners to 15-20 ft-lbs (20.3-27.1 Nm).

Install protective caps (6) on screw ends.

See

Figure 4-8

. Install vent hose onto fuel tank vent nipple.

10. Connect the fuel pump connector [141] housings.

sm06571a

1. Fuel pump wiring harness
2. Cable clip mounting boss on ECM caddy
3. Cable clip
4. Wire harness caddy latch clip
5. Fuel pump wiring harness loop
6. Fuel pump module

Figure 4-10. Fuel Pump Wiring Harness Routing

CONNECTING FUEL HOSE AND FILLING
FUEL TANK

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

See

Figure 4-7

. Connect fuel hose.

Push up on release sleeve (1).

Push fuel hose fitting (2) into fuel pump module fuel
pump quick-connect fitting.

Pull down on release sleeve to lock quick-connect
fitting.

Tug on fuel hose fitting to make sure it is securely
locked in place.

See

Figure 4-8

. Install vent hose onto vent nipple on fuel

tank.

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Fill fuel tank and carefully inspect for leaks around fuel
pump module.

Install main fuse.

Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting. Turn
ignition switch OFF.

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

Install seat.

VAPOR VALVE

Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks
due to excessive pressure can cause a fire or explosion,
which could result in death or serious injury. (00265a)

See

Figure 4-11

. The fuel tank is vented through a standpipe

(vent tube) within the tank. A hose (1) at the base of the fuel
tank is connected to the standpipe.

Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)

HOME

4-10 2013 Sportster Service: Fuel System

Harley Davidson 2013 Sportster Models. Service Manual - page 23