Harley Davidson 2013 Sportster Models. Service Manual

NOTE

Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed. Install other
IAC mounting screw but do not tighten at this time.

See

Figure 4-38

. Install cable bracket (3) onto induction

module (4):

Obtain

new

screws (1, 2) or apply LOCTITE 243

MEDIUM

STRENGTH

THREADLOCKER

AND

SEALANT (blue) to existing screws.

Install both screws finger-tight.

Tighten both IAC mounting screws to 60

in-lbs

(6.8

Nm). Tighten side screw (1) to 60

in-lbs

(6.8 Nm).

Install fuel injectors, fuel rail and fuel hose. See

4.15 FUEL

INJECTORS

INSTALLATION

TORQUE VALUE

FASTENER

10.2-13.6 Nm

90-120

in-lbs

Induction module mounting
bracket screw: XL models

10.9-13.6 Nm

96-120

in-lbs

Intake manifold mounting
screw: XL models

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL
Models

See

Figure 4-34

. Make sure two mounting screws (2) are

screwed into heads two or three turns.

See

Figure 4-40

. Install mounting flanges (1) on intake

manifold (5) with counterbore (2) facing away from mani-
fold and open slotted ends of flanges facing away from
induction module (6).

Place a

new

seal (3) into each mounting flange with the

beveled edge (4) facing the mounting flange counterbore.

NOTE

When induction module is positioned on manifold mounting
screws, Verify the flanges are correctly installed on the mani-
fold. Verify the rubber seals are in place.

Place induction module assembly in position between
engine heads. Slide open slotted ends of mounting flanges
under heads of two mounting screws on left side of engine.

See

Figure 4-35

. Holding induction module/intake manifold

assembly in place, install two mounting screws (3) into
remaining mounting flange holes. Tighten all four screws
finger-tight.

See

Figure 4-31

. Install mounting bracket (1) and screw

(2). Tighten screw finger-tight.

Temporarily install two breather screws through mounting
bracket. Thread breather screws into cylinder heads finger-
tight. This will properly line up induction module assembly.

Tighten mounting bracket screws to 90-120

in-lbs

(10.2-

13.6 Nm).

Tighten all four intake manifold mounting screws to 96-
120

in-lbs

(10.9-13.6 Nm).

10. See

Figure 4-37

. Install idle cable barrel (4) into throttle

wheel (6). Slide idle cable (3) through slot (5) and wind
around groove in throttle wheel.

11. Pull cable through slot in cable guide (7). Slide spring (2)

and end of idle cable housing (1) down into cable guide.

12. See

Figure 4-36

. Install throttle cable barrel (6) into throttle

wheel (7). Slide throttle cable through slot (8) and wind
around groove in throttle wheel.

13. Pull cable through slot (4) in cable guide (3). Slide end of

throttle cable housing (1) down into cable guide.

14. Adjust throttle and idle cables. See

1.13 THROTTLE

CONTROL

sm01590

1. Mounting flange (2)
2. Counterbore
3. Seal (2)
4. Beveled edge
5. Intake manifold
6. Induction module

Figure 4-40. Installing Mounting Flange and Seal

HOME

2013 Sportster Service: Fuel System 4-27

15.

EVAP Controlled Models:

See

Figure 4-41

. Install purge

hose onto fitting (2) on induction module (1).

16. See

Figure 4-42

. Plug in the following connectors:

Front fuel injector (1) connector [84],

Rear fuel injector (2) connector [85],

TMAP sensor (3) connector [80],

IAC (4) connector [87],

TPS (5) connector [88].

17. Remove prop from under rear of fuel tank. Lower rear of

fuel tank into position. Install fastener, washer and nut in
fuel tank rear mounting holes. Tighten to 15-20 ft-lbs (20.3-
27.1 Nm). Install protective caps on screw ends. See

4.4 FUEL TANK: XL MODELS

18. Install air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

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)

19. Connect fuel hose to fuel pump module. Fill fuel tank.

Carefully check for leaks around fuel pump module. See

4.4 FUEL TANK: XL MODELS

20. Install main fuse.

21. Close left side cover.

22. Turn ignition switch to ON and OFF to reset IAC to park

position.

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)

23. Install seat.

sm06574

1. Induction module
2. Purge hose (to canister) fitting

Figure 4-41. Purge Hose Fitting: CA Models

sm06873a

1. Front fuel injector [84A]
2. Rear fuel injector [85A]
3. TMAP sensor [80A]
4. IAC [87A]
5. TPS [88A]

Figure 4-42. Induction Module Electrical Connectors

HOME

4-28 2013 Sportster Service: Fuel System

4.9

INDUCTION MODULE: XR 1200X

REMOVAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.5 FUEL TANK: XR 1200X

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

Remove main fuse.

Remove fuel tank and air box. See

4.5 FUEL TANK: XR

1200X

and

4.3 AIR CLEANER ASSEMBLY, XR 1200X

See

Figure 4-43

. Remove screws (3), fastener (1) and

fastener (2).

Pull cover away from induction module and disengage
cable retainer from back side of cover. Remove cover.

Disengage throttle cables from induction module. See

2.28 THROTTLE CABLES: ALL MODELS

See

Figure 4-44

. Unplug the following connectors:

Front fuel injector (3) [84],

Rear fuel injector (4) [85],

TMAP sensor (5) [80],

IAC (6) [87],

TPS (7) [88].

EVAP Controlled Models:

Remove purge hose from fitting

(8).

See

Figure 4-45

. Disconnect oil line flare nuts (1) from

flare fittings (2) in cylinder heads. Remove flare fittings (2)
from cylinder heads.

10. Loosen but do not remove left side screws holding induc-

tion module to cylinder head.

11. Remove two screws (3) securing induction module to cyl-

inder heads on right side of vehicle.

12. Remove induction module from engine.

sm06774b

1. Fastener, wire form
2. Fastener, to induction module
3. Screws (2)

Figure 4-43. Induction Module Cover: XR 1200X

HOME

2013 Sportster Service: Fuel System 4-29

sm04954

1. Induction module
2. Throttle cable bracket
3. Front fuel injector [84A]
4. Rear fuel injector [85A]
5. TMAP sensor [80A]
6. IAC [87A]
7. TPS [88A]
8. Purge hose fitting (EVAP models only)
9. Fuel supply hose
10. Throttle wheel
11. Fuel rail (not visible)

Figure 4-44. Induction Module

sm05420a

1. Flare nuts
2. Flare fittings
3. Fastener

Figure 4-45. Remove Induction Module

DISASSEMBLY

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

See

Figure 4-46

. Remove retainer (7). Remove fuel rail

(8) with hose (4) and injectors (10) from the induction
module.

Remove hose (4) and injectors (10) from fuel rail.

Remove cable bracket (12).

NOTE

Screws (16) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.

Remove IAC (3). See

4.10 IDLE AIR CONTROL (IAC),

Removal: XR 1200X

Remove TMAP (15), and TPS (1).

Remove mounting flanges (14) and seals (13).

HOME

4-30 2013 Sportster Service: Fuel System

sm05421

1. TPS
2. O-ring
3. IAC
4. Fuel hose
5. Nylon washer (included with hose (4))
6. O-ring (included with hose (4))
7. Retainer
8. Fuel rail
9. O-ring (4) (included in hardware and O-ring kit)
10. Fuel injector (2)
11. Screw
12. Throttle cable bracket
13. Intake seal
14. Mounting flange
15. TMAP sensor
16. Screw, IAC (2)

Figure 4-46. Induction Module

ASSEMBLY

TORQUE VALUE

FASTENER

6.8 Nm

in-lbs

IAC mounting screw: XR
1200X

6.8 Nm

in-lbs

Throttle cable bracket screw:
XR 1200X

See

Figure 4-46

. Install the following:

TPS. See

4.6 THROTTLE POSITION SENSOR

(TPS)

TMAP sensor. See

4.11 TEMPERATURE MANIFOLD

ABSOLUTE PRESSURE (TMAP) SENSOR

IAC. See

4.10 IDLE AIR CONTROL (IAC)

NOTE

Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed. Install other
IAC mounting screw but do not tighten at this time.

Install cable bracket (12) onto induction module:

Apply

LOCTITE

243

MEDIUM

STRENGTH

THREADLOCKER AND SEALANT (blue) to the
threads of screw (11).

Install screw finger-tight.

Tighten both IAC mounting screws to 60

in-lbs

(6.8

Nm).

Tighten screw (11) to 60

in-lbs

(6.8 Nm).

Install fuel injectors, fuel rail and fuel hose. See

4.15 FUEL

INJECTORS

INSTALLATION

TORQUE VALUE

FASTENER

10.3-13.6 Nm

90-120

in-lbs

Intake manifold mounting
screw: XR 1200X

29.8-35.3 Nm

22-26 ft-lbs

Cylinder head oil feed flare fit-
ting: XR 1200X

17.6-23.0 Nm

13-17 ft-lbs

Cylinder head oil feed line
flare nut: XR 1200X

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover to cyl-
inder head sockethead bolts:
XR 1200X

10.2-13.6 Nm

90-120

in-lbs

Induction module cover to
induction module fastener: XR
1200X

10.2-13.6 Nm

90-120

in-lbs

Induction module cover to wire
form fastener: XR 1200X

Install the two left side mounting screws two or three turns
into the heads.

See

Figure 4-47

. Install mounting flanges (3) on induction

module with counterbore (1) facing toward the engine.

Install

new

seals (4).

Placed the beveled edge facing the mounting flange
counterbore.

Rotate the flange to the slotted mounting hole is on
the same side as the IAC solenoid.

NOTES

•

Verify that the flanges are installed on the manifold.

•

Verify that the rubber seals are in place.

See

Figure 4-45

. Place induction module assembly in

position between engine heads. Slide open slotted ends
of mounting flanges under heads of two mounting screws
on left side of engine.

While holding induction module assembly in place, install
two mounting screws (3) into remaining mounting flange
holes. Tighten all four screws finger-tight.

Tighten to 90-120

in-lbs

(10.3-13.6 Nm).

Inspect O-rings on flare fittings (2). Replace as necessary.

Install flare fittings in cylinder heads. Tighten to 22-26 ft-
lbs (29.8-35.3 Nm).

HOME

2013 Sportster Service: Fuel System 4-31

Connect oil line flare nuts (1) to flare fittings (2). Tighten
to 13-17 ft-lbs (17.6-23.0 Nm).

10. Install throttle cables. See

2.28 THROTTLE CABLES: ALL

MODELS

11. Adjust throttle and idle cables. See

1.13 THROTTLE

CONTROL

sm05423

1. Beveled counterbore
2. Beveled edge
3. Mounting flange
4. Tapered seal

Figure 4-47. Mounting Flange and Seal

12.

EVAP Controlled Models:

See

Figure 4-44

. Install purge

hose onto fitting (8) on induction module (1).

NOTE

XR 1200X: See

Figure 4-48

. The fuel injector harness leads

must NEVER be routed between the retaining bracket (3) and
the induction module body (4). Improper routing will result in
chafing of the insulation resulting in poor engine performance.

13. See

Figure 4-44

. Plug in the following connectors:

Front fuel injector (3) [84],

Rear fuel injector (4) [85],

TMAP sensor (5) [80],

IAC (6) [87],

TPS (7) [88].

14. Secure TPS harness to cover with a

new

cable strap with

anchor.

15. Install induction module cover. Finger tighten the fasteners.

16. Tighten:

Socket headbolts to 20-24 ft-lbs (27.1-32.5 Nm).

Cover-to-induction module fastener to 90-120

in-lbs

(10.2-13.6 Nm).

Cover-to-wire form fastener to 90-120

in-lbs

(10.2-

13.6 Nm).

17. Install air box. See

4.3 AIR CLEANER ASSEMBLY, XR

1200X

18. Install fuel tank. See

4.4 FUEL TANK: XL MODELS

19. Fill fuel tank. Check for leaks around fuel pump module

and quick connector. See

4.4 FUEL TANK: XL MODELS

20. Install main fuse.

21. Close left side cover.

22. Reset IAC to park.

Turn ignition to ON.

Turn ignition to OFF.

23. Start engine. Check for fuel leaks.

sm06875

1. Front fuel injector [84]
2. Rear fuel injector [85]
3. Retaining bracket
4. Induction module

Figure 4-48. Fuel Injectors and Retaining Bracket

HOME

4-32 2013 Sportster Service: Fuel System

4.10

IDLE AIR CONTROL (IAC)

GENERAL

XL Models:

See

Figure 4-49

XR 1200X:

See

Figure 4-50

The ECM uses the IAC to control engine idle speed. See the
electrical diagnostic manual.

sm06869a

Figure 4-49. IAC: XL Models

sm06870a

Figure 4-50. IAC: XR 1200X

REMOVAL: XL MODELS

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

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

Remove main fuse.

Remove air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

See

Figure 4-51

. Unplug harness connector [87B] from

IAC connector [87A] (1).

NOTE

Heat screws (2) to soften the thread sealant and avoid
breakage during removal. Use ONLY HEAT GUN (Part No. HD-
25070) to heat the screws. NEVER use an open flame.

HOME

2013 Sportster Service: Fuel System 4-33

Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:

Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.

Heat remaining screw for one minute. Remove screw.

See

Figure 4-52

. Grasp IAC and rotate clockwise until IAC

mounting tab (1) clears throttle cable bracket (2).

With a gentle twisting motion, pull IAC straight out of
induction module body.

sm01629

1. IAC Connector [87A]
2. Screw (2)
3. IAC
4. Throttle cable bracket

Figure 4-51. IAC Removal/Installation: XL Models

sm01630

1. IAC mounting tab (2) (rotated 45 degrees)
2. Throttle cable bracket

Figure 4-52. Removing/Installing IAC: XL Models

INSTALLATION: XL MODELS

TORQUE VALUE

FASTENER

6.8 Nm

in-lbs

IAC mounting screw: XL
models

See

Figure 4-53

. If re-using IAC (1), inspect O-ring (2) for

cuts, tears or signs of deterioration. Replace IAC if O-ring
is damaged.

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)

Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.

Apply a thin coat of

clean

engine oil to O-ring.

See

Figure 4-52

. Rotate IAC approximately 45 degrees

clockwise so IAC mounting tab will clear throttle cable
bracket (2) when IAC is installed.

With a gentle twisting motion, insert IAC into induction
module.

Rotate IAC so that harness connector faces intake mani-
fold and mounting tab is underneath tab on throttle cable
bracket.

Install IAC.

See

Figure 4-51

. Apply a drop of LOCTITE 243

MEDIUM

STRENGTH

THREADLOCKER

AND

SEALANT (blue) to the threads of each screw (2).

Install two screws (2).

Use a six-point socket (not a Torx wrench). Tighten
to 60

in-lbs

(6.8 Nm).

Plug harness connector [87B] into IAC connector [87A]
(1).

Install air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

10. Install main fuse.

11. Close left side cover.

HOME

4-34 2013 Sportster Service: Fuel System

sm01632

1. IAC
2. O-ring
3. Pintle

Figure 4-53. IAC and O-ring

REMOVAL: XR 1200X

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

NOTE

It is not necessary to remove the fuel tank, air box or induction
module from the vehicle in order to replace the IAC.

Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.5 FUEL TANK: XR 1200X

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

Remove main fuse.

See

Figure 4-54

. Unplug harness connector [87B] from

IAC connector [87A] (1).

NOTE

Screws (2) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.

Using a six-point socket (not a Torx wrench), remove two
screws (2) in the following order:

Heat fastener nearest to throttle bracket for two
minutes using HEAT GUN (Part No. HD-25070).
Remove screw.

Heat remaining screw for one minute and remove.

See

Figure 4-55

. Grasp IAC and rotate counterclockwise

until IAC mounting tab (1) clears throttle cable bracket (2).

With a gentle twisting motion, pull IAC straight out of
induction module body.

sm04969

1. IAC Connector [87A]
2. Screw (2)
3. IAC
4. Throttle cable bracket

Figure 4-54. IAC Removal/Installation: XR 1200X

HOME

2013 Sportster Service: Fuel System 4-35

sm04970

1. IAC mounting tab (2) (rotated 45 degrees)
2. Throttle cable bracket

Figure 4-55. Removing/Installing IAC: XR 1200X

INSTALLATION: XR 1200X

TORQUE VALUE

FASTENER

6.8 Nm

in-lbs

IAC mounting screw: XR
1200X

See

Figure 4-53

. If re-using IAC (1), inspect O-ring (2) for

cuts, tears or signs of deterioration. Replace IAC if O-ring
is damaged.

Clean all locking agent from the threads of the attachment
screws and holes. Blow debris from screw holes using
low-pressure compressed air.

Apply a thin coat of

clean

engine oil to O-ring.

See

Figure 4-55

. Rotate IAC approximately 45 degrees

counterclockwise so IAC mounting tab will clear throttle
cable bracket (2) when IAC is installed.

With a gentle twisting motion, insert IAC into induction
module.

Rotate IAC so that harness connector points straight down
and mounting tab is underneath tab on throttle cable
bracket.

Install the IAC.

See

Figure 4-54

. Apply a drop of LOCTITE 243

MEDIUM

STRENGTH

THREADLOCKER

AND

SEALANT (blue) to the threads of each screw (2).

See

Figure 4-54

. Install two screws (2).

Use a six-point socket (not a TORX wrench). Tighten
to 60

in-lbs

(6.8 Nm).

Plug harness connector [87B] into IAC connector [87A]
(1).

Connect fuel hose to fuel pump module. See

4.5 FUEL

TANK: XR 1200X

10. Install main fuse.

11. Close left side cover.

12. Turn on ignition switch and start motorcycle. Carefully

check for leaks around fuel hose fitting.

HOME

4-36 2013 Sportster Service: Fuel System

4.11

TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR

GENERAL

See

Figure 4-56

Figure 4-57

. The Temperature Manifold

Absolute Pressure (TMAP) sensor performs the dual functions
of monitoring air temperature and air pressure in the intake
manifold. See the electrical diagnostic manual.

sm06852

Figure 4-56. TMAP Location: XL Models

sm01622a

Figure 4-57. TMAP Location: XR 1200X

REMOVAL: XL MODELS

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)

Remove main fuse.

Remove air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

Remove fuel rail and fuel injectors. See

4.15 FUEL

INJECTORS

. This will allow access to the two screws that

secure the induction module to the intake manifold.

See

Figure 4-56

. Remove two screws (2) and separate

induction module from intake manifold. See

4.8 INDUC-

TION MODULE: XL MODELS

See

Figure 4-58

. Pull induction module away from intake

manifold far enough so that TMAP sensor retaining bracket
(1) clears TMAP sensor body (2).

Unplug harness connector [80B] from TMAP connector
[80A] (3).

Grasp TMAP sensor and with a gentle twisting motion,
pull sensor straight up out of intake manifold body.

HOME

2013 Sportster Service: Fuel System 4-37

sm01623

1. TMAP sensor retaining bracket
2. TMAP sensor
3. Sensor connector [80A]
4. O-ring

Figure 4-58. TMAP Sensor Removal/Installation

INSTALLATION: XL MODELS

TORQUE VALUE

FASTENER

4.0 Nm

in-lbs

Induction module screw: XL
Models

See

Figure 4-59

. If re-using TMAP sensor (1), inspect O-

ring (2) in groove of sensor for cuts, tears or signs of
deterioration. Replace if necessary.

Apply a thin coat of

clean

engine oil to TMAP sensor O-

ring.

See

Figure 4-58

. With a gentle twisting motion, insert

sensor (2) into intake manifold with connector [80A] (3)
facing rear cylinder head.

Plug harness connector [80B] into TMAP sensor.

Inspect O-ring (4) between induction module and intake
manifold for cuts, tears or signs of deterioration. Install

new

O-ring if necessary. Make certain O-ring is fully

seated in its grove in induction module body.

Mate induction module to intake manifold. Secure with two
screws. Tighten to 35

in-lbs

(4.0 Nm).

Install fuel injectors and fuel rail. See

4.15 FUEL

INJECTORS

Install air cleaner assembly. See

4.3 AIR CLEANER

ASSEMBLY

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)

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)

Connect fuel hose to fuel pump module.

10. Fill fuel tank. Carefully check for leaks around fuel pump

module. See

4.4 FUEL TANK: XL MODELS, Connecting

Fuel Hose and Filling Fuel Tank

11. Install main fuse.

12. Close left side cover.

sm01624

1. TMAP sensor
2. O-ring

Figure 4-59. TMAP Sensor

REMOVAL: XR 1200X

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

Remove main fuse.

NOTE

See

Figure 4-60

. The TMAP sensor harness and TPS harness

are attached to inside of induction module cover. It is not
necessary to remove the retainer securing these harnesses to
the induction module cover in order to access TMAP sensor.

Remove screws (3) and the wire form (1) and induction
module fastener (2).

HOME

4-38 2013 Sportster Service: Fuel System

Carefully rotate induction module cover out of the way.

Unplug TMAP sensor harness connector [80B].

See

Figure 4-61

. Remove screw (2).

Grasp TMAP sensor (1) and with a gentle twisting motion,
pull sensor straight up out of induction module body.

sm06774b

1. Fastener, wire form
2. Fastener, to induction module
3. Screws (2)

Figure 4-60. Induction Module Cover: XR 1200X

sm04998b

1. TMAP sensor [80A]
2. Screw

Figure 4-61. TMAP Sensor: XR 1200X

INSTALLATION: XR 1200X

TORQUE VALUE

FASTENER

9.0 Nm

in-lbs

TMAP sensor screw

27.1-32.5 Nm

20-24 ft-lbs

Induction module cover to cyl-
inder head fastener: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Induction module cover to
induction module fastener: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Wire form to induction module
cover fastener: XR 1200X

If re-using TMAP sensor, inspect O-ring for cuts, tears or
signs of deterioration. Replace if necessary.

Apply a thin coat of

clean

engine oil to TMAP sensor O-

ring.

With a gentle twisting motion, insert sensor into induction
module with connector [80A] pointing down. Secure sensor
to induction module with screw. Tighten to 80

in-lbs

(9.0

Nm).

Plug sensor harness connector [80B] into TMAP sensor.

See

Figure 4-60

. Install the induction module cover.

Rotate cover between cylinder heads.

Install all fasteners finger-tight.

Verify cover alignment before proceeding.

Tighten socket head screws (3) to 20-24 ft-lbs (27.1-
32.5 Nm).

Tighten fastener (2) to 84-108

in-lbs

(9.5-12.2 Nm).

Tighten fastener (1) to 84-108

in-lbs

(9.5-12.2 Nm).

Install main fuse.

HOME

2013 Sportster Service: Fuel System 4-39

4.12

OXYGEN (O2) SENSOR

GENERAL

See

Figure 4-62

. The O2 sensors are installed in threaded

bosses on the inboard side of the front and rear exhaust pipes.
For O2 sensor troubleshooting, see the electrical diagnostic
manual.

sm01642

1. Front O2 sensor
2. Rear O2 sensor

Figure 4-62. O2 Sensor Locations: XL Models

REMOVAL

TOOL NAME

PART NUMBER

OXYGEN SENSOR SOCKET

HD-48262

OXYGEN SENSOR SOCKET

HD-48647

All Models:

See

Figure 4-63

. Disconnect the front O2

sensor connector:

Remove the frame clip (2).

Disconnect the sensor pin connector [138A] housing
(3) from the socket connector [138B] housing.

XL Models:

See

Figure 4-64

. Disconnect the rear O2

sensor connector:

Remove the rear O2 sensor connector [137] (2) from
the ECM caddy (1).

Disconnect the rear O2 sensor pin connector [137A]
housing from the socket connector [137B] housing.

XR 1200X:

Disconnect the rear O2 sensor pin connector

[137A] housing from the socket connector [137B] housing.

NOTE

If O2 sensors are to be reused:

•

Mark each sensor FRONT or REAR.

•

Do not damage the sensor wire harness.

Remove the front and rear sensor:

XL Models:

Use the OXYGEN SENSOR SOCKET

(Part No. HD-48262).

XR 1200X:

Use the OXYGEN SENSOR SOCKET

(Part No. HD-48647).

sm01643

1. Front O2 sensor
2. Frame clip
3. O2 sensor connector [138]

Figure 4-63. Front O2 Sensor and Connector (XL shown)

sm06882

1. ECM caddy cover
2. O2 sensor

Figure 4-64. Rear Oxygen Sensor: XL Models

HOME

4-40 2013 Sportster Service: Fuel System

INSTALLATION

TOOL NAME

PART NUMBER

OXYGEN SENSOR SOCKET

HD-48262

OXYGEN SENSOR SOCKET

HD-48647

TORQUE VALUE

FASTENER

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

NOTES

•

Do not install O2 sensors that have been dropped or
impacted by other components. Damage to the sensor
element may have occurred.

•

New O2 sensors have threads coated with anti-seize
material.

•

If a sensor is being reused, apply a thin coat of ANTI-
SEIZE LUBRICANT to the sensor threads and install new
seal rings.

•

Do not use any other grease or sealant product on sensor
threads.

Install the front and rear sensors:

XL Models:

Use the OXYGEN SENSOR SOCKET

(Part No. HD-48262) to install the front and rear O2
sensors.

XR 1200X:

Use the OXYGEN SENSOR SOCKET

(Part No. HD-48647) to install the front and rear O2
sensors.

Tighten to 29-44 ft-lbs (39.3-59.7 Nm).

NOTE

The O2 connector must be clean and free of any dielectric
grease.

All Models:

Route the front O2 wire harness:

Connect the pin and socket connector [138] housings.

Install the frame clip over the sensor harness, clutch
cable, and wiring harness on left frame down tube.

NOTE

Route rear O2 sensor harness toward left side in a loop away
from the exhaust system. Avoid contact with exhaust port or
exhaust pipe.

XL Models:

Route the rear O2 sensor wire harness:

Connect the pin and socket connector [137] housings.

Route the wire harness and snap the connector into
the ECM caddy.

Slide the caddy into place and tighten the fastener.

XR 1200X:

Route sensor harness and connect pin and

socket connector [137] housings.

HOME

2013 Sportster Service: Fuel System 4-41

4.13

EXHAUST SYSTEM: XL MODELS

GENERAL

TOOL NAME

PART NUMBER

SNAP-ON WRENCH

PFSX916

To facilitate removing exhaust pipe header nuts, use SNAP-
ON WRENCH (Part No. PFSX916).

sm02198

23.

12.

Screw

Heat shield, rear exhaust pipe

Muffler, front

24.

13.

Muffler, rear

Engine sprocket cover

Worm drive clamp (5)

14.

25.

Muffler heat shield (2) (HDI,
England, Japan, Brazil) (2)

Exhaust pipe, front

Screw

26.

Washer

Exhaust pipe, rear

15.

27.

Worm drive clamp (4)

Muffler interconnect bracket

Front O2 sensor assembly

28.

16.

Rear O2 sensor assembly

Flanged bolt (4)

Torca muffler clamp assembly
(2)

29.

17.

Seal ring (2)

Screw (3)

18.

Exhaust port gasket (2)

30.

Washer (3)

O2 sensor connectors (2):
[137], [138]

19.

Muffler interconnect gasket (2)

Exhaust gasket retaining ring
(2)

31. Heat shield, rear exhaust pipe

(mid-control vehicles only)

20. Exhaust pipe clamp

21.

Exhaust pipe flange (2)

Exhaust pipe clamp bracket

22.

10.

Acorn nut

Nut (4)

11. Heat shield, front exhaust

pipe

Figure 4-65. Exhaust System, All XL Models

HOME

4-42 2013 Sportster Service: Fuel System

Harley Davidson 2013 Sportster Models. Service Manual - page 25