Harley Davidson 2013 Sportster Models. Service Manual - page 26

. Remove heat shields:

Models with Mid Controls:

Remove worm drive

clamps (13) from heat shield (12) completely. Remove
bottom heat shield.

All Models:

Open worm drive clamps (13) and

remove exhaust pipe heat shields (11, 12).

HDI, England, Asia Pacific, India, Japan, Brazil
Models:

Open worm drive clamps (15) and remove

muffler heat shields (14).

Unplug O2 sensor connectors (30). Front connector [138]
is mounted on left front frame downtube. Rear connector
[137] is attached to the ECM caddy on the left.

Remove nuts (10) from front and rear cylinder head
exhaust studs.

Remove flanged bolts (16) securing front and rear mufflers
(1, 2) to muffler interconnect bracket (5).

Loosen Torca muffler clamp assemblies (6) on front and
rear mufflers. Remove mufflers. Discard muffler intercon-
nect gaskets (19).

Remove and discard Torca clamps.

NOTE

New Torca muffler clamps have eliminated the need for silicone
or graphite tape during assembly. Always use new clamps
during installation to maintain sealing integrity and prevent
leakage.

Remove nut (22) and screw (23) from exhaust pipe clamp
(20). Separate exhaust pipe clamp from clamp bracket
(21).

Remove front and rear exhaust pipes (3, 4). Slide exhaust
pipe clamp off rear exhaust pipe.

Remove exhaust port gasket (7), retaining ring (8) and
exhaust pipe flange (9) from each exhaust pipe. Discard
gasket.

10. Remove O2 sensor assemblies (27, 28) from front and

rear exhaust pipes. Discard seal rings (29). See

4.12 OXYGEN (O2) SENSOR

sm04380

1. Top heat shield
2. Bottom heat shield
3. Upper worm drive clamp
4. Lower worm drive clamp

Figure 4-66. Rear Exhaust Pipe Heat Shields: Vehicles with

Mid Controls

Muffler Interconnect Bracket

See

Figure 4-67

. Remove screw (6), washer (5) and

exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).

See

Figure 4-68

. Remove rear brake rod (1) at bell crank

(2).

See

. Remove three screws (17) and washers

(18) securing muffler interconnect bracket (5) to engine
crankcase. Remove muffler interconnect bracket.

sm02202

1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw

Figure 4-67. Sprocket Cover

2013 Sportster Service: Fuel System 4-43

sm02199

1. Rear brake rod
2. Bell crank
3. Rear brake master cylinder assembly
4. Rear brake pedal
5. Frame

Figure 4-68. Rear Brake Linkage

INSTALLATION

TOOL NAME

PART NUMBER

SNAP-ON SWIVEL BALL SOCKET
EXTENSION

PFSX916

TORQUE VALUE

FASTENER

40.7-44.7 Nm

30-33 ft-lbs

Muffler interconnect bracket
mounting screw: XL Models

13.6-20.4 Nm

120-180

in-lbs

Brake rod to bell crank screw

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket
screw: XL Models

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

39.3-59.7 Nm

29-44 ft-lbs

O2 sensor

20.4-25.8 Nm

15-19 ft-lbs

Muffler to interconnect bracket
screw: XL Models

10.9-13.6 Nm

96-120

in-lbs

Cylinder head exhaust port nut

51.6-58.4 Nm

38-43 ft-lbs

Muffler torca clamp nut

27.1-40.7 Nm

20-30 ft-lbs

Exhaust pipe clamp nut: XL
Models

2.3-4.5 Nm

20-40

in-lbs

Exhaust heat shield clamps

Muffler Interconnect Bracket

See

. Install muffler interconnect bracket (5)

to engine case with three screws (17) and washers (18).
Tighten to 30-33 ft-lbs (40.7-44.7 Nm).

See

Figure 4-68

. Apply two drops of LOCTITE 243

MEDIUM STRENGTH THREADLOCKER AND SEALANT
(blue) to rear brake rod ball stud screw. Attach rear brake
rod (1) to bell crank (2). Tighten screw to 120-180

in-lbs

(13.6-20.4 Nm).

See

Figure 4-67

. Install sprocket cover (1). Install but do

not tighten the screws (2, 3). Note that long screw goes
in top hole, short screw in bottom hole.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120

in-lbs

(9.0-13.6 Nm).

Exhaust Pipes and Mufflers

NOTES

•

To facilitate installing exhaust pipe header nuts, use
SNAP-ON SWIVEL BALL SOCKET EXTENSION (Part
No. PFSX916).

•

If reusing the O2 sensors, apply a thin coat of ANTI-SEIZE
LUBRICANT to the threads prior to installation. Do not
use any other grease or sealant product on sensor threads.

•

The electrical connector must also be clean and free of
dielectric grease.

See

. If the front and rear O2 sensor assem-

blies (27, 28) are being reused, install

new

seal rings (29)

onto each sensor. Apply a thin coat of ANTI-SEIZE LUB-
RICANT to the sensor threads.

4-44 2013 Sportster Service: Fuel System

Install sensor assemblies into front and rear exhaust pipes.
Tighten to 29-44 ft-lbs (39.3-59.7 Nm). See

4.12 OXYGEN

(O2) SENSOR

Place exhaust pipe flange (9), exhaust gasket retaining
ring (8) and

new

exhaust port gasket (7) over front end of

each exhaust pipe (3, 4). Position flange so that inside
counterbore faces cylinder head exhaust port.

Position front ends of front and rear exhaust pipes into
front and rear cylinder heads, respectively. Position holes
in flanges over mounting studs and loosely install nuts
(10). Do not tighten nuts at this time.

Install exhaust pipe clamp (20) on rear exhaust pipe (4)
with square hole facing down. Assemble exhaust pipe
clamp to exhaust pipe clamp bracket (21) with screw (23)
and acorn nut (22). Verify that the bracket fits between
ends of clamp. Do not tighten at this time.

Install

new

muffler interconnect gaskets (19) in intercon-

nect mating holes in mufflers (1, 2).

Place

new

Torca clamp assemblies (6) over slotted end

of each muffler. Install each muffler onto the end of its
respective exhaust pipe.

Rotate both mufflers until their mounting bosses line up
with holes in muffler interconnect bracket. Carefully mate
each muffler with exhaust port in interconnect bracket.
Loosely install flanged bolts (16). Do not tighten at this
time.

Tighten exhaust system fasteners in the following
sequence:

Tighten four flanged bolts securing mufflers to inter-
connect bracket to 15-19 ft-lbs (20.4-25.8 Nm).

Tighten four nuts at cylinder head exhaust studs to
96-120

in-lbs

(10.9-13.6 Nm).

Tighten two Torca clamps to 38-43 ft-lbs (51.6-58.4
Nm).

Tighten rear exhaust pipe clamp nut (22) to 20-30 ft-
lbs (27.1-40.7 Nm).

10. Plug in O2 sensor connectors (30). Front connector [138]

is mounted on left front frame downtube. Rear connector
[137] is attached to the left side of the ECM caddy. See

4.12 OXYGEN (O2) SENSOR

11. Install heat shields:

Open worm drive clamps (13) and install heat shields
(11, 12) on exhaust pipes. Position each clamp so
that screw is on the outboard side in the most
accessible position.

Models with Mid Controls:

See

Figure 4-66

. Tighten

lower worm drive clamp (4) a few turns. Slide lower
portion of bottom heat shield (2) into lower worm drive
clamp. Engage upper portion of bottom heat shield
into upper worm drive clamp (3).

All Models:

Tighten all exhaust pipe heat shield

clamps to 20-40

in-lbs

(2.3-4.5 Nm).

HDI, England, Asia Pacific, India, Japan and Brazil
Models:

Open worm drive clamps (15). Install the

muffler heat shields (14). Position each clamp so that
screw is on the outboard side in the most accessible
position. Tighten clamps securely.

2013 Sportster Service: Fuel System 4-45

4.14

EXHAUST SYSTEM: XR 1200X

GENERAL

TOOL NAME

PART NUMBER

SNAP-ON WRENCH

PFSX916

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

sm05463

17.

Flanged nut

Sleeve

Fastener, rear muffler mount

18.

10.

Fastener, mount to frame

Lower clamp

Fastener, interconnect bracket
(3)

19.

Fastener, front muffler mount

Muffler gasket (2)

11.

20.

Interconnect bracket

Lower muffler

Flat washer

21.

12.

Grommet, front mount (2)

Upper muffler

Nut (4)

13.

22.

Retaining ring (2)

Fastener, front muffler mount
(2)

Rear muffler mount

23.

14.

Bolt, muffler-to-muffler (2)

Exhaust port gasket (2)

15.

Front muffler mount

Exhaust pipe flange (2)

16.

Carriage bolt

Washer-nut

Figure 4-69. Exhaust System: XR 1200X

REMOVAL

Mufflers

See

. Remove forward muffler mount fastener

(3) and washer-nut (8).

Remove two bolts (23) fastening mufflers together.

Slide upper muffler (21) back off header pipe to remove.

Remove rear muffler mount fastener (1).

4-46 2013 Sportster Service: Fuel System

Rotate lower muffler (20) counterclockwise to disengage
from the rear mount (22) and slide back off header pipe
to remove.

Remove mount grommets (5) and sleeve (9).

Inspect rear mount (22) and replace if damaged.

Inspect muffler seals (19) and replace if necessary:

Pull seal out of muffler using a hook-type tool.

Push

new

seal into place being careful not to distort

or damage the new seal.

Header Pipes

Remove mufflers.

Disconnect O2 sensor connectors. Remove sensor if
necessary. See

4.12 OXYGEN (O2) SENSOR

See

. Loosen or remove head pipe heat shields

to gain access to header pipe flange nuts (12).

Remove flange nuts (12) and pull flanges (15) off from
studs.

Remove nut (17) and carriage bolt (16) from lower clamp
(18).

NOTE

Be careful not to drop or hit header pipe assembly. Damage
to the catalytic converter may result.

Remove header pipe assembly from vehicle.

Inspect exhaust port gasket (14) and replace if necessary.

Pry gasket from exhaust port in cylinder head being
careful not to damage the bore.

Push

new

gasket into place with the larger ID facing

the header pipe, as shown in the inset in

Remove retainer rings (13) and flanges (15) if necessary.

If necessary, remove mount brackets (7, 22) and intercon-
nect bracket (11).

INSTALLATION

TORQUE VALUE

FASTENER

20.3-27.1 Nm

15-20 ft-lbs

Muffler mount to frame, rear
fastener: XR 1200X

61.0-67.8 Nm

45-50 ft-lbs

Muffler mount to frame, front
fastener: XR 1200X

40.7-44.7 Nm

30-33 ft-lbs

Interconnect bracket to frame
fastener: XR 1200X

10.8-13.6 Nm

96-120

in-lbs

Exhaust flange nut: XR 1200X

40.7-44.7 Nm

30-33 ft-lbs

Exhaust clamp, lower nut: XR
1200X

13.6-20.3 Nm

120-180

in-lbs

Muffler to front muffler mount
fastener: XR 1200X

13.6-20.3 Nm

120-180

in-lbs

Muffler to muffler bolt: XR
1200X

13.6-20.3 Nm

120-180

in-lbs

Muffler to rear muffler mount
fastener: XR 1200X

2.3-4.5 Nm

20-40

in-lbs

Exhaust heat shield clamps

See

. If removed, install flanges (15) and

retaining rings (13).

If removed, install rear mount (22), front mount (7) and
interconnect bracket (11).

Tighten fasteners (2) to 15-20 ft-lbs (20.3-27.1 Nm).

Tighten fasteners (6) to 45-50 ft-lbs (61.0-67.8 Nm).

Tighten fasteners (10) to 30-33 ft-lbs (40.7-44.7 Nm).

NOTE

Do not damage exhaust port gaskets (14) when positioning
header pipes in exhaust port area.

Install

new

exhaust port gaskets (14).

Install head pipe assembly in position and loosely secure
lower clamp (18) with carriage bolt (16) and flange nut
(17).

Install flanges (15) and finger-tighten nuts (12). Do not
tighten until mufflers are installed.

Install mufflers.

Place lower muffler (20) on header pipe. Rotate until rear
mount fastener (1) can be installed. Loosely install fastener
(1).

Place upper muffler (21) on header pipe.

Install muffler-to-muffler bolts (23) finger-tight.

10. Install grommets (5), sleeve (9), fastener (3), washer (4)

and washer nut (8). Tighten finger-tight.

11. Tighten the exhaust flange nuts (12) to 96-120

in-lbs

(10.8-13.6 Nm) in the following sequence:

The front exhaust pipe lower exhaust flange nut

The front exhaust pipe upper exhaust flange nut

The rear exhaust pipe lower exhaust flange nut

The rear exhaust pipe upper exhaust flange nut

2013 Sportster Service: Fuel System 4-47

12. Verify the exhaust header pipes do not contact the drive

belt idler pulley. Verify that there is sufficient clearance for
proper operation of the rear brake pedal. Tighten nut (17)
to 30-33 ft-lbs (40.7-44.7 Nm).

13. Tighten fastener (3) to 120-180

in-lbs

(13.6-20.3 Nm).

14. Tighten muffler to muffler bolts (23) to 120-180

in-lbs

(13.6-20.3 Nm).

15. Tighten rear mount fastener (1) to 120-180

in-lbs

(13.6-

20.3 Nm).

16. Install heat shields. Tighten to 20-40

in-lbs

(2.3-4.5 Nm).

17. Install and connect the O2 sensors. See

4.12 OXYGEN

(O2) SENSOR

4-48 2013 Sportster Service: Fuel System

4.15

FUEL INJECTORS

REMOVAL

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)

Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
in death or serious injury. (000621b)

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.

XL Models with 4.5 gal

(

17.0 L

)

fuel tank

: Access to the

fuel injectors and fuel rail may be easier if the fuel tank is
raised up as follows:

Remove seat.

Loosen (but do not remove) front fuel tank mounting
screw. Remove rear fuel tank mounting screw,
washers and nut. See

Place a clean shop cloth between front of fuel tank
and front fork upper bracket to protect fuel tank finish.
Carefully pivot rear of fuel tank upward and prop in
position with a block of soft wood or other suitable
device.

See

. Unplug engine sub-harness connectors

from fuel injector connectors [84A], [85A] (7, 8).

Remove screw (5) and retaining bracket (2).

If replacing either the fuel supply hose (1) or fuel rail (6),
disassemble as follows:

Hold fuel rail in place.

With a gentle twisting motion, pull fuel supply hose
straight up out of fuel rail.

Hold fuel injectors (9, 10) in place by pressing down on
harness connectors (7, 8) and with a gentle rocking motion,
pull fuel rail off injectors.

With a gentle twisting motion, pull fuel injectors out of
intake manifold (XL models) or induction module (XR
1200X).

Remove and discard O-rings (11).

sm06857

1. Fuel supply hose
2. Retaining bracket
3. Fuel rail
4. Front fuel injector and connector
5. Rear fuel injector and connector

Figure 4-70. Fuel Injector Assembly Location: XL Models

2013 Sportster Service: Fuel System 4-49

sm06858

1. Fuel supply hose
2. Retaining bracket
3. Fuel rail (not visible)
4. Front fuel injector and connector
5. Rear fuel injector and connector

Figure 4-71. Fuel Injector Assembly Location: XR 1200X

sm06567

1. Fuel supply hose
2. Retaining bracket
3. Sealing washer (only available with fuel supply

hose)

4. O-ring (only available with fuel supply hose)
5. Screw
6. Fuel rail
7. Front injector connector [84A]
8. Rear injector connector [85A]
9. Front fuel injector
10. Rear fuel injector
11. O-ring (4) (provided in repair kit)
12. Intake manifold

Figure 4-72. Fuel Injector Assemblies: XL Models

INSTALLATION

TORQUE VALUE

FASTENER

6.8 Nm

in-lbs

Fuel hose retaining bracket
screw

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank fasteners: XL
Models

See

. Apply a thin coat of clean engine oil to

new

fuel injector O-rings (11). Install O-rings onto fuel

injectors (9, 10).

With harness connectors (7, 8) facing up, push fuel
injectors into intake manifold (XL models) or induction
module (XR 1200X).

See

Figure 4-70

Figure 4-71

. Rotate fuel injectors so

that harness connectors are positioned as shown.

4-50 2013 Sportster Service: Fuel System

Gently press fuel rail onto free end of fuel injectors. Press
fuel rail down until hole in fuel rail molded-in bracket lines
up with mounting hole in intake manifold (12).

If the fuel supply hose and fuel rail were separated in the
disassembly procedure, reassemble:

See

. Inspect sealing washer (3) and O-

ring (4) for damage. If either require replacement,
install a

new

fuel line kit.

Lightly coat O-ring with clean engine oil. Push fuel
supply hose into fuel rail bore until collar on hose is
flush with top of fuel rail.

See

. Install retaining bracket (2) and fastener

(5) as follows:

See

Figure 4-73

. Orient fuel supply hose so that loc-

ating flange (2) is positioned as shown.

Install retaining bracket (3). Fit the U-shaped opening
in bracket around fuel supply hose and locating
flange.

See

. Secure retaining bracket (2) with

screw (5). Tighten to 60

in-lbs

(6.8 Nm).

NOTES

•

XL Models: See

Figure 4-70

. The fuel injector harness

leads are mounted between the bracket and induction
module.

•

XR 1200X: See

Figure 4-71

. Do not route the fuel injector

harness leads between the retaining bracket (2) and
induction module body. Improper routing will result in
chafing of the insulation resulting in poor engine perform-
ance.

Connect engine sub-harness connectors to the fuel
injectors. Verify that the wire harnesses are routed outside
the wings of retaining bracket (2) on XR 1200X.

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)

XL Models with 4.5 gal

(

17.0 L

)

Fuel Tank:

if the fuel

tank was raised up to gain access to the fuel injectors,
install fuel tank and seat:

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 front and rear fasteners to 15-20 ft-lbs (20.3-
27.1 Nm).

Install protective caps on screw ends. See

Install seat.

Connect fuel hose to fuel pump module. Fill fuel tank.
Check for leaks around fuel pump module. See

10. Install main fuse.

11. Close left side cover.

sm06568

1. Fuel supply hose
2. Locating flange
3. Retaining bracket
4. Fuel rail

Figure 4-73. Mounting Fuel Hose and Fuel Rail: XL Models

2013 Sportster Service: Fuel System 4-51

4.16

FUEL PUMP

GENERAL

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)

Do not replace the special Teflon coated fuel pump wiring
with ordinary bulk wire. Ordinary insulation materials can
deteriorate when put in contact with gasoline and cause
an explosion, which could result in death or serious injury.
(00566b)

Carefully inspect fuel hose for cuts, tears, holes or other
damage. Replace hose if any damage is found. Even a small
hole can cause a reduction in fuel pressure.

REMOVAL

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 4-74

. Unplug fuel pump harness connector

[141] (1), located forward of fuse/relay block on left side
of vehicle.

Drain and remove fuel tank from vehicle. See

See

Figure 4-75

. Lay fuel tank upside-down on a soft cloth.

Remove five screws (3).

Carefully lift fuel pump module out of fuel tank. See

Figure 4-76

. To facilitate removal, tilt module when it is

almost completely free of fuel tank.

See

Figure 4-74

. Remove and discard cover plate seal

(7).

sm06721

1. Fuel pump harness connector [141]
2. Fuel pump
3. Fuel filter housing
4. Sending unit float
5. Quick-connect fitting
6. Cover plate
7. Cover plate seal

Figure 4-74. Fuel Pump Module

4-52 2013 Sportster Service: Fuel System

12323

1. Fuel tank
2. Fuel pump module
3. Screw (5)
4. Fuel pump harness
5. Quick-connect fitting

Figure 4-75. Fuel Pump Module: All Models

sm01571

Figure 4-76. Removing/Installing Fuel Pump Module: All

Models

DISASSEMBLY

The disassembly procedure consists of the following groups:

•

Pressure regulator and filter housing.

•

Fuel pump assembly and pump bracket.

•

Low fuel level sensor assembly.

•

Fuel pump.

sm06722

1. Cable strap (3)
2. Pump assembly clamp
3. Pump bracket
4. Filter housing hose

Figure 4-77. Fuel Pump Cable Straps and Pump Clamp

NOTE

See

Figure 4-77

. Maintain the relative positions of the wiring

harness cable straps (1) and pump assembly clamp (2).

Pressure Regulator and Filter Housing

See

. Remove cable strap (1) securing wiring

harness to the filter housing hose (4).

See

. Remove ground clip (12) from top of filter

housing (23).

Remove and discard clamp (1). Remove filter housing
hose from top of fuel pump (2).

Remove retaining clip (24) from top of filter housing and
remove pressure regulator (22).

Remove second retaining clip (24) from bottom of filter
housing and remove filter housing. Remove fuel filter ele-
ment (25) from housing.

Remove O-ring (26) from filter housing mount (19).

2013 Sportster Service: Fuel System 4-53

Fuel Pump Assembly and Pump Bracket

See

. Make note of the location of any cable

straps securing wiring harness to the fuel pump bracket
(3). Remove cable straps.

See

. Unplug fuel pump harness connector

[86] (13).

Unplug low fuel level sensor connector from fuel
pump/sender harness (14).

Remove and discard clamp (1). Remove filter housing
hose (11) from top of fuel pump (2).

Remove and discard pump assembly clamp (7). Remove
pump assembly with pump insulator (3) from pump bracket
(5).

Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket.

Remove three screws w/lockwashers (6) and remove
pump bracket from cover plate (9).

Low Fuel Level Sensor Assembly

See

. Make note of the location of cable strap

(1) securing low fuel level sensor connector to filter
housing hose (4). Remove cable strap.

See

. Unplug the fuel pump/sender harness

connector (15) from the low fuel level sensor (17).

Remove push nut (16) and low fuel level sensor assembly
(17) from pump bracket (5).

ASSEMBLY

TORQUE VALUE

FASTENER

2.1-4.1 Nm

19-36

in-lbs

Fuel pump bracket mounting
screw

The assembly procedure consists of the following groups:

•

Low fuel level sensor assembly.

•

Fuel pump assembly and pump bracket.

•

Pressure regulator and filter housing.

Low Fuel Level Sensor Assembly

NOTE

The low fuel lamp will not turn off until there is sufficient fuel in
the tank, the ignition switch has been turned off and on and
the motorcycle has begun forward speed.

See

. Install low fuel level sensor assembly

(17) onto pump bracket (5). Secure with push nut (16).

Plug the fuel pump/sender harness connector (15) into
the low fuel level sensor (17).

See

. Secure low fuel level sensor connector

and fuel pump/sender harness to filter housing hose (4)
with cable strap (1).

Fuel Pump Assembly and Pump Bracket

See

. Install pump bracket (5) onto cover plate

(9). Secure with three screws w/lockwashers (6). Tighten
to 19-36

in-lbs

(2.1-4.1 Nm).

Install low fuel level sensor assembly (17) onto pump
bracket. Secure with push nut (16).

Install fuel pump assembly (2) with pump insulator (3) onto
pump bracket. Secure with pump assembly clamp (7) (for
relative position of clamp, see

Install filter housing hose (11) on top of fuel pump. Secure
with clamp (1).

Plug in fuel pump harness connector [86] (13).

See

. Secure fuel pump/sender harness to fuel

pump bracket (3) with cable straps (1).

Pressure Regulator and Filter Housing

See

. Install the

new

O-ring onto filter housing

mount (19).

Install fuel filter element (25) into filter housing (23). Install
filter housing onto filter housing mount. Secure with
retaining clip (24) at bottom of housing, making sure that
clip is oriented exactly as shown in

Install pressure regulator (22) on top of filter housing.
Secure with second retaining clip (24), making sure that
clip is oriented exactly as shown in

Install filter housing hose (11) on top of fuel pump (2).
Secure with clamp (1).

Install ground clip (12) on top of filter housing.

See

. Secure fuel pump/sender harness to

filter housing hose (4) with cable strap (1).

4-54 2013 Sportster Service: Fuel System

sm01611a

15.

Low fuel level sensor connector

Clamp

16.

Fuel pump

Push nut

17.

Low fuel level sensor

Pump insulator

18.

Cover plate seal

Retaining ring

19.

Filter housing mount

Pump bracket

20.

Screw w/lockwasher (3)

Screw (5)

21.

Fuel outlet quick-connect fitting

Pump assembly clamp

22.

Inlet sock

Pressure regulator

23.

Filter housing

Cover plate

10.

24.

Fuel pump/sender harness connector [141]

Retaining clip (2)

25.

11.

Fuel filter element

Filter housing hose

12.

26.

Ground clip

O-ring

27.

13.

Cable strap

Fuel pump harness connector [86]

14. Fuel pump/sender harness

Figure 4-78. Fuel Pump and Sender Assembly

INSTALLATION

TORQUE VALUE

FASTENER

4.5-5.1 Nm

40-45

in-lbs

Fuel pump module mounting
screw

See

. Install

new

cover plate seal (4) into

groove in cover plate (9).

See

Figure 4-76

. Carefully install fuel pump module into

fuel tank.

Tilt module.

Lower it into fuel tank.

Straighten module to complete installation.

See

Figure 4-79

. Install screws. Tighten to 40-45

in-lbs

(4.5-5.1 Nm) in sequence.

Install fuel tank. See

Verify that the fuel pump harness fits in wire harness
caddy latch clip with loop in harness between latch
clip and fuel pump module.

Plug in fuel pump harness connector [141].

Connect vent hose to fuel tank vent nipple.

Connect fuel hose to fuel tank. Fill fuel tank. Check for
leaks around fuel pump module. See

4.4 FUEL TANK: XL

MODELS

Install main fuse.

Close left side cover.

2013 Sportster Service: Fuel System 4-55

Check for leaks:

Turn ignition switch to ON.

Verify fuel pump is activated.

Check for leaks at quick connect.

Turn ignition switch to OFF.

sm07444

Figure 4-79. Fuel Pump Module Torque Sequence

4-56 2013 Sportster Service: Fuel System

4.17

FUEL FILTER ELEMENT

GENERAL

The fuel filter element is located in the fuel pump assembly
inside the fuel tank.

Check fuel system hose and fittings for leaks.

REMOVAL

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

4.5 FUEL TANK: XR

1200X

Remove seat.

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

Remove main fuse.

Drain and remove fuel tank. See

4.4 FUEL TANK: XL

MODELS

Remove fuel pump assembly from fuel tank. See

4.16 FUEL PUMP

See

Figure 4-80

. Remove and discard cover plate seal

(6).

Remove retaining clip (4) and lift filter housing (5) off fuel
pump assembly (1).

Remove and discard filter element (3).

INSTALLATION

TORQUE VALUE

FASTENER

4.5-5.1 Nm

40-45

in-lbs

Fuel pump module mounting
screw

See

Figure 4-80

. Install a

new

O-ring (2).

Install

new

filter element (3) into filter housing (5).

Install filter housing onto base of fuel pump assembly (1).
Secure with retaining clip (4), making sure that clip is ori-
ented right side up, exactly as shown in the figure.

Install

new

cover plate seal (6) into groove in cover plate

(7).

Install fuel pump assembly into fuel tank. Tighten mounting
screws in a cross pattern to 40-45

in-lbs

(4.5-5.1 Nm).

See

4.16 FUEL PUMP

Install fuel tank and reconnect fuel hose. See

. Fill

fuel tank and carefully check for leaks.

Install main fuse.

Install seat.

Turn ignition switch ON. Verify fuel pump operation.

sm06645

1. Fuel pump assembly
2. O-ring
3. Fuel filter element
4. Retaining clip
5. Filter housing
6. Cover plate seal
7. Cover plate

Figure 4-80. Replacing Fuel Filter Element

2013 Sportster Service: Fuel System 4-57

4.18

FUEL PRESSURE TEST

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

The fuel pump delivers fuel to the fuel hose, a cavity in the
induction module that supplies the fuel injectors, and to the
pressure regulator. Excess fuel pressure is bypassed to the
fuel tank through the pressure regulator.

The fuel pump can be turned on with DIGITAL TECHNICIAN
II (Part No. HD-48650).

Improper fuel system pressure may contribute to one of the
following conditions:

•

Cranks, but does not run.

•

Cuts out (may feel like ignition problem).

•

Hesitation, loss of power or poor fuel economy.

TESTING

TOOL NAME

PART NUMBER

FUEL PRESSURE GAUGE

HD-41142

FUEL PRESSURE GAUGE ADAPTER

HD-44061

Connect the Fuel Pressure Gauge

Purge the fuel supply hose and disconnect the fuel supply
hose from the fuel pump module.

XL Models:

See

XR 1200X:

See

Connect the fuel pump connector [141].

NOTE

Do not kink the fuel hose when installing or removing fuel
pressure gauge and adapter.

See

Figure 4-81

. Attach the FUEL PRESSURE GAUGE

ADAPTER (Part No. HD-44061) as follows:

See

Figure 4-82

. Pull up on sleeve of fuel tank quick-

connect fitting (2) and insert neck of the fuel pressure
gauge adapter (3) into quick-connect fitting.

Push up on bottom of adapter and pull down on sleeve
until it clicks. Tug on adapter to verify that it is locked
in place.

In the same manner, connect vehicle's fuel supply
hose fitting (1) to quick-connect fitting (4) on the
adapter.

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)

Verify that the fuel valve (6) and air bleed petcock on the
fuel pressure gauge are closed.

See

Figure 4-83

. Remove protective cap from free end of

fuel pressure gauge adapter.

Connect the FUEL PRESSURE GAUGE (Part No. HD-
41142) to the Schroeder valve.

Perform Test

Start and idle engine to pressurize the fuel system. Open
the fuel valve to allow the flow of fuel down the hose of
the pressure gauge.

Purge air from gauge and hose:

Position the clear air bleed tube in a suitable con-
tainer.

Open and close the air bleed petcock to purge the
gauge and hose of air.

Repeat this step several times until only solid fuel
(without bubbles) flows from the air bleed tube.

Close the petcock.

Open and close throttle to change engine speed. Note the
reading of the pressure gauge.

Turn the engine OFF and service as necessary. Refer to

Table 4-3

sm01654a

1. Quick-connect fitting
2. Protective cap
3. Fuel tank fitting (neck)

Figure 4-81. Fuel Pressure Gauge Adapter (Part No.

HD-44061)