Harley Davidson 2013 Sportster Models. Service Manual

sm04993b

Figure 3-29. Return Oil Manifold Fastener

Installation

Install

new

O-rings in manifold assembly and apply a light

film of oil to them.

Start return oil manifold on rigid lines and install rear cyl-
inder head oil line in quick connect fitting. Verify that it is
securely held by the retainer clip.

See

Figure 3-29

. Slide oil manifold onto rigid lines and

secure with screw (1). Tighten to 84-108

in-lbs

(9.5-12.2

Nm).

Connect oil return hose to oil tank. Secure with clamp.

Install and connect oil tank drain hose. Install and secure
plug in drain hose.

Connect battery positive (+) cable to starter. See

6.10 STARTER

Install battery. See

1.22 BATTERY MAINTENANCE

Fill the oil tank. See

1.6 ENGINE OIL AND FILTER

CYLINDER HEAD OIL RETURN LINES

TOOL NAME

PART NUMBER

OIL LINE REMOVER, 3/8 INCH

HD-49096

TORQUE VALUE

FASTENER

12.2-17.6 Nm

108-156

in-lbs

Oil line quick connect fitting,
cylinder head return: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Oil line retainer, front, nut: XR
1200X

9.5-12.2 Nm

84-108

in-lbs

Oil rigid line retainer, rear,
screw: XR 1200X

Removal

Remove return oil manifold. See

3.12 PRECISION

COOLING SYSTEM: XR 1200X, Return Oil Manifold

See

Figure 3-30

. Remove fastener (1) and raise retainer

until alignment pin (2) is clear of bore in crankcase. Roll
retainer out from beneath rigid oil lines to remove.

See

Figure 3-31

. Remove nut (1) and washer.

Separate front oil line (2) from cylinder head using OIL
LINE REMOVER, 3/8 INCH (Part No. HD-49096).

Separate rear oil line (3) from cylinder head using OIL
LINE REMOVER, 3/8 INC (Part No. HD-49096).

If front oil line needs to be completely removed, remove
starter. See

6.10 STARTER

If necessary, remove quick connect fitting from cylinder
head.

sm04994a

1. Fastener
2. Alignment pin (hidden)

Figure 3-30. Rigid Oil Line Retainer

sm06544

1. Locknut
2. Front oil line
3. Rear oil line

Figure 3-31. Cylinder Head Oil Lines

Installation

NOTE

Used O-rings can leak. Always install new O-rings when per-
forming repairs.

If removed from cylinder head, install quick connect fittings
with

new

O-rings. Tighten to 108-156

in-lbs

(12.2-17.6

Nm).

Install

new

internal O-rings in quick connect fittings.

If removed, place front cylinder head oil line on engine
and install electric starter. See

6.10 STARTER

HOME

2013 Sportster Service: Engine 3-45

NOTE

Apply a light film of oil to the end of the line before inserting it
into the fitting.

See

Figure 3-31

. Connect front oil line (2) to cylinder head.

Verify that it is securely held by the retainer clip.

Secure front line to crankcase with locknut (1) and washer.
Tighten to 84-108

in-lbs

(9.5-12.2 Nm).

Install retainer.

See

Figure 3-30

. Roll retainer under rigid lines at rear

of crankcase.

Orient alignment pin to bore in case.

Verify that the flanges on lines are on the manifold
side of the retainer.

Secure with fastener (1).

Tighten to 84-108

in-lbs

(9.5-12.2 Nm).

Install return oil manifold. See

3.12 PRECISION COOLING

SYSTEM: XR 1200X, Return Oil Manifold

See

Figure 3-31

. Connect rear oil line (3) to cylinder head.

Verify that it is securely held by the retainer clip.

CYLINDER HEAD OIL FEED ASSEMBLY

TORQUE VALUE

FASTENER

20.3-28.5 Nm

15-21 ft-lbs

Check valve plug fitting: XR
1200X

10.3-13.6 Nm

90-120

in-lbs

Check valve housing fastener:
XR 1200X

29.8-35.3 Nm

22-26 ft-lbs

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

18-23 Nm

13-17 ft-lbs

Cylinder head oil feed line
flare nut: XR 1200X

Removal

Disconnect the battery. See

1.22 BATTERY MAINTEN-

ANCE

Drain oil tank. See

1.6 ENGINE OIL AND FILTER

See

Figure 3-32

. Disconnect flare nuts (1) from each cyl-

inder head.

Pull oil feed hose connector (2) straight up to remove feed
hose assembly from check valve assembly (3).

Remove two fasteners (4) and check valve assembly (3).

See

Figure 3-33

. Carefully clamp assembly in vise and

remove plug fitting (7).

Remove spring (5) and ball (4).

If necessary, remove flare fittings from cylinder heads.

Inspect components for wear or damage and replace as
necessary.

sm04998a

1. Feed oil line flare nut
2. Feed oil line connector
3. Check valve assembly
4. Fastener

Figure 3-32. Cylinder Head Oil Feed Assembly

sm04999a

1. Base O-ring
2. Check valve housing
3. O-ring
4. Check ball
5. Spring cartridge assembly
6. O-ring
7. Plug fitting

Figure 3-33. Check Valve Components

Installation

See

Figure 3-33

. Install ball (4) and spring (5) into housing

(2).

NOTE

Used O-rings can leak. Always install new O-rings when per-
forming repairs.

Install

new

O-ring (6) on check valve plug fitting (7) and

install fitting. Tighten to 15-21 ft-lbs (20.3-28.5 Nm).

Install

new

O-ring (3) in bore of housing.

HOME

3-46 2013 Sportster Service: Engine

Install housing (2) with

new

base O-ring (1). Tighten

fasteners to 90-120

in-lbs

(10.3-13.6 Nm).

If removed, apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to the flare fit-
tings. Install in cylinder heads with

new

O-rings. Tighten

to 22-26 ft-lbs (29.8-35.3 Nm).

NOTE

Apply a light film of oil to the end of the line before inserting it
into the fitting.

See

Figure 3-32

. Push oil feed hose assembly straight

down to install. Connect oil line flare nuts (1) to cylinder
head flare fittings. Hold lines to prevent rotation and tighten
to 13-17 ft-lbs (18-23 Nm).

Install and connect battery. See

1.22 BATTERY MAINTEN-

ANCE

Fill oil tank. See

1.6 ENGINE OIL AND FILTER

OIL PUMP LINES

TOOL NAME

PART NUMBER

OIL LINE REMOVER, 1/2 INCH

HD-46503

OIL LINE REMOVER, 3/8 INCH

HD-49096

TORQUE VALUE

FASTENER

12.2-17.6 Nm

108-156

in-lbs

Oil pump quick connect fitting:
XR 1200X

10.2-13.6 Nm

90-120

in-lbs

Oil rigid line retainer, rear,
screw: XR 1200X

Removal

Remove return oil manifold. See

3.12 PRECISION

COOLING SYSTEM: XR 1200X, Return Oil Manifold

Remove retainer.

See

Figure 3-34

. Remove fastener (1).

Raise retainer until alignment pin (2) is clear of bore
in crankcase.

Roll retainer out from beneath rigid oil lines.

See

Figure 3-35

. Remove return oil line (1) from gearcase

cover using OIL LINE REMOVER, 3/8 INCH (Part No. HD-
49096).

If removing the return oil line, remove starter. See

6.10 STARTER

Remove feed oil line (2) from gearcase cover using OIL
LINE REMOVER, 1/2 INCH (Part No. HD-46503).

Disconnect vent hose (3) from fitting on oil pump.

See

Figure 3-36

. Remove locknut (1) and washer. Remove

oil cooler line retainer (2) from lines.

See

Figure 3-35

. Release each oil cooler line (4, 5) from

bottom of gearcase cover using OIL LINE REMOVER, 1/2
INCH (Part No. HD-46503).

If necessary, remove quick connect fittings.

sm04994a

1. Fastener
2. Alignment pin (hidden)

Figure 3-34. Rigid Oil Line Retainer

sm04996

1. Oil pump return line
2. Oil pump feed line
3. Vent hose
4. Oil cooler line, to cooler
5. Oil cooler line, from cooler

Figure 3-35. Oil Pump Lines

sm06937

1. Fastener
2. Line retainer (partially hidden)

Figure 3-36. Oil Cooler Line Retainer

HOME

2013 Sportster Service: Engine 3-47

Installation

NOTE

Used O-rings can leak. Always install new O-rings when per-
forming repairs.

If removed, install quick connect fittings with

new

O-rings.

Tighten to 108-156

in-lbs

(12.2-17.6 Nm).

Install

new

O-rings in quick connect fittings.

NOTE

Apply a light film of oil to the end of each line before inserting
it into the fitting.

See

Figure 3-35

. Connect oil cooler lines (4, 5) to lower

gearcase cover. Verify each is securely held by the retainer
clip.

See

Figure 3-36

. Install oil cooler line retainer (2) and

tighten fastener (1) securely.

See

Figure 3-35

. If removed, place return line (1) on

engine and install starter. See

6.10 STARTER

Connect vent (3), feed oil (2) and return oil (1) lines to oil
pump body and cam support. Verify each is securely held
by the retainer clip.

Remove retainer.

See

Figure 3-34

. Roll retainer under rigid lines at rear

of crankcase.

Orient alignment pin (2) to bore in case.

Verify flanges on lines are on the manifold side of the
retainer.

Secure with screw (1).

Tighten to 90-120

in-lbs

(10.2-13.6 Nm).

Install return oil manifold. See

3.12 PRECISION COOLING

SYSTEM: XR 1200X, Return Oil Manifold

Fill oil tank. See

1.6 ENGINE OIL AND FILTER

OIL COOLER

TOOL NAME

PART NUMBER

OIL LINE REMOVER, 1/2 INCH

HD-46503

TORQUE VALUE

FASTENER

4.1-6.8 Nm

36-60

in-lbs

Oil cooler fastener: XR 1200X

Removal

Disconnect the battery. See

1.22 BATTERY MAINTEN-

ANCE

Drain oil tank. See

1.6 ENGINE OIL AND FILTER

Using OIL LINE REMOVER, 1/2 INCH (Part No. HD-
46503), separate oil cooler lines from oil cooler.

See

Figure 3-37

. Remove fasteners (1) securing oil cooler

to frame brackets.

Remove oil cooler from motorcycle.

If necessary, remove oil cooler rigid lines from gearcase
cover. See

3.12 PRECISION COOLING SYSTEM: XR

1200X, Oil Pump Lines

sm04953

1. Fastener (2)
2. Oil cooler mount (2)

Figure 3-37. Oil Cooler Mounts

Installation

NOTE

Used O-rings can leak. Always install new O-rings when per-
forming repairs.

Install

new

O-rings in quick connect fittings.

If removed, install oil cooler rigid lines. See

3.12 PRECI-

SION COOLING SYSTEM: XR 1200X, Oil Pump Lines

NOTE

See

Figure 3-38

. Position oil cooler parallel with down tubes

as shown. Do not orient oil cooler forward of down tubes or
clutch cable damage will result.

See

Figure 3-37

. Secure oil cooler to frame brackets.

Tighten fasteners (1) to 36-60

in-lbs

(4.1-6.8 Nm).

NOTE

Apply a light film of oil to the end of the line before inserting it
into the fitting.

Connect oil lines to oil cooler fittings. Verify that each is
securely held by the retainer clip.

Fill the oil tank. See

1.6 ENGINE OIL AND FILTER

Connect the battery. See

1.22 BATTERY MAINTENANCE

HOME

3-48 2013 Sportster Service: Engine

3.13

TOP END OVERHAUL: DISASSEMBLY

GENERAL

This section describes disassembling the top end of the engine,
from the cylinder deck up. To perform a complete top end
overhaul, follow all steps listed in this section.

Then follow all steps listed in the following sections, including
inspection and repair procedures: See

3.14 CYLINDER HEAD

and

3.15 CYLINDER AND PISTON

NOTE

Clean engine before disassembly. Abrasive particles can
damage machined surfaces or plug oil passageways. Remove
all dirt and particles before disassembly to prevent component
damage.

STRIPPING MOTORCYCLE FOR TOP END
REPAIR

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)

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

4.4 FUEL TANK: XL MODELS

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.

Unplug O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers. See

4.13 EXHAUST SYSTEM:

XL MODELS

4.14 EXHAUST SYSTEM: XR 1200X

Disconnect spark plug cables from spark plugs.

Drain and remove fuel tank. See

4.4 FUEL TANK: XL

MODELS

4.5 FUEL TANK: XR 1200X

Remove horn.

Front Mount:

See

6.32 HORN, Replacement: Front

Mount

Side Mount:

See

6.32 HORN, Replacement: Side

Mount

Remove air cleaner assembly:

XL Models except XL 1200V:

Remove cover, air

filter and air cleaner backing plate. See

4.3 AIR

CLEANER ASSEMBLY, XL Models except XL 1200V

XL 1200V:

Remove cover, air filter and air cleaner

backing plate. See

4.3 AIR CLEANER ASSEMBLY,

XL 1200V

CA Models:

Remove EVAP purge hose from induc-

tion module. See

4.20 EVAPORATIVE EMISSIONS

CONTROL

Remove induction module. See

4.8 INDUCTION MODULE:

XL MODELS

4.9 INDUCTION MODULE: XR 1200X

10. Secure induction module assembly and throttle cables out

of the way.

11. See

Figure 3-39

. Remove upper front stabilizer link and

frame bracket:

Remove screw (4) securing stabilizer link (2) to engine
bracket (1).

Remove screws (5) and washers (8). Remove horn
bracket (9) (models with front mounted horn) and
frame bracket (3) with stabilizer link.

sm01472

1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lock washer (2)
8. Washer (2)
9. Horn bracket

Figure 3-39. Upper Front Stabilizer Link Assembly

HOME

3-50 2013 Sportster Service: Engine

CYLINDER HEADS

Disassembling Rocker Covers

Prevent engine damage. Washers and fasteners used in
the engine are hardened parts. Do not use unhardened
parts. (00544b)

Remove spark plugs.

See

Figure 3-42

. Remove four screws with captive

washers (1) and sealing washers (2). Discard sealing
washers.

Remove outer rocker cover (3) or (20).

Remove and discard gaskets (4, 5).

Rotate crankshaft until both valves are closed on head
being removed.

See

Figure 3-40

. Remove hardware securing inner rocker

cover to cylinder head in the following order.

Remove two screws and washers (1).

Remove three bolts and washers (2).

Loosen four rocker arm bolts (3) in 1/4-1/2 turn
increments using a cross pattern. This relieves valve
spring pressure evenly on inner rocker cover.

See

Figure 3-42

. Remove inner rocker cover (8) or (24).

Remove and discard gasket (16).

Remove breather assembly:

XL Models:

Remove screw (6), breather assembly

(7) and breather seal (17). Discard seal.

XR 1200X:

Push breather assembly (23) and O-ring

(22) out from the under side.

NOTE

Mark rocker arm shafts for reassembly in their original positions.
Install valve train components in their original positions or
increased engine wear may result.

See

Figure 3-41

. Remove rocker arm shafts by tapping

them out using a hammer and a soft metal punch.

10. See

Figure 3-42

. Remove rocker arms (11, 12). Mark the

rocker arms for reassembly in their original locations.

sm06546a

1. Screws and washers
2. Bolts and washers
3. Rocker arm bolts

Figure 3-40. Inner Rocker Cover Fasteners (typical)

sm06547

1. Retaining notch
2. Position of rocker arm retaining bolts

Figure 3-41. Removing Rocker Arm Shafts (typical)

HOME

2013 Sportster Service: Engine 3-51

sm01473

13.

Bolt (4)

Screw w/captive washer (4)

14.

Sealing washer (4)

Screw (2)

15.

Bolt (3)

Outer rocker cover: XL Models

16.

Gasket

17.

Breather seal: XL Models

Gasket

18.

Screw

Breather location: Front Cylinder: XL Models

19.

Breather location: Rear Cylinder: XL Models

Breather assembly: XL Models

20.

Inner rocker cover: XL Models

Outer rocker cover: XR 1200X

21.

Breather hose fitting hole: XR 1200X

Rocker arm shaft (2)

10.

22.

Rocker arm bushing (4)

O-ring: XR 1200X

23.

11.

Breather filter and valve assembly: XR 1200X

Rocker arm

12.

24.

Rocker arm

Inner rocker cover: XR 1200X

Figure 3-42. Rocker Cover Assembly

Removing Cylinder Head

NOTE

See

Figure 3-43

Figure 3-44

. Follow sequence of incremental

removal as described below to prevent component damage.

XR 1200X:

Remove precision cooling lines. See

3.12 PRECISION COOLING SYSTEM: XR 1200X, Cyl-
inder Head Oil Return Lines

See

Figure 3-43

and

Figure 3-44

. Loosen each head bolt

1/8-turn following the sequence shown.

HOME

3-52 2013 Sportster Service: Engine

Continue loosening in 1/8-turn increments until screws are
loose. Remove head screws.

Remove cylinder head and head gasket. Discard head
gasket.

sm01476

1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt

Figure 3-43. Front Cylinder Headbolt Torque Sequence

sm03780

1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt

Figure 3-44. Rear Cylinder Headbolt Torque Sequence

Disassembling Pushrods and Covers

See

Figure 3-45

. Remove pushrod covers (2), O-rings (1,

3) and pushrods (4). Mark the location and orientation (top
and bottom) of each pushrod. Discard O-rings.

Remove socket screws (5) and washers (6). Remove
tappet cover (7) and gasket (8). Discard gasket.

sm01587a

1. O-ring (4)
2. Pushrod cover (4)
3. O-ring (4)
4. Pushrod (4)
5. Screw (8)
6. Washer (8)
7. Tappet cover (2)
8. Gasket (2)
9. Screw (2)
10. Anti-rotation device (2)
11. Tappet (4)
12. Right crankcase

Figure 3-45. Middle Valve Train Components

HOME

2013 Sportster Service: Engine 3-53

CYLINDER AND PISTON

TOOL NAME

PART NUMBER

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

PISTON PIN REMOVER

HD-42320-A

PISTON SUPPORT PLATE

HD-42322

Clean engine before disassembly.

See

Figure 3-46

. Rotate crankshaft until piston (6) of cyl-

inder being removed is at bottom of its stroke.

sm01492

1. Piston pin bushing
2. Connecting rod
3. Lock ring (2)
4. Piston pin
5. Piston ring set
6. Piston
7. Cylinder
8. Cylinder stud (4)
9. Cylinder base gasket
10. Dowel (2)
11. Head gasket

Figure 3-46. Cylinder and Piston

Carefully raise cylinder just enough to permit placing clean
towel under piston to prevent any foreign matter from
falling into crankcase.

NOTE

If cylinder does not come loose, tap lightly with rawhide or
plastic hammer perpendicular to cylinder fins. Never try to pry
cylinder up.

Carefully lift cylinder over piston and cylinder studs (8).
Do not allow piston to fall against cylinder studs.

NOTE

To avoid damage to piston assembly and/or cylinder studs, do
not allow piston to fall against studs.

Discard cylinder base gasket (9).

NOTE

With cylinder removed, be careful not to bend the cylinder
studs. The slightest bend could cause a stress riser and could
lead to stud failure.

Install a 6.0 in (150 mm) length of 1/2 in (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the pistons.

Handle piston with extreme care. The alloy used in these
pistons is very hard. Any scratches, gouges or other marks
in the pistons could score the cylinder during engine
operation and cause engine damage. (00546b)

Wear safety glasses or goggles when removing or
installing piston pin retaining rings. Piston pin retaining
rings are compressed in the ring groove and can fly out
when removed from the groove, which could result in
serious eye injury. (00293a)

See

Figure 3-47

. Remove piston pin lock ring as follows:

I n s e r t

P I S TO N

P I N

L O C K

R I N G

REMOVER/INSTALLER (Part No. HD-34623-C) into
piston pin bore until claw on tool is positioned in slot
of piston (directly under lock ring).

Squeeze handles of tool together and pull from bore.
Hold a shop towel over bore during removal in the
event that the lock ring should fly out. Remove lock
ring from claw and discard.

NOTES

•

It is not necessary to remove both piston pin lock rings
during piston removal. Leave second lock ring in piston
pin bore.

•

Do not reuse piston pin lock rings. Removal may weaken
lock rings and they may break or dislodge if reused, res-
ulting in engine damage.

HOME

3-54 2013 Sportster Service: Engine

sm01496

1. Piston pin lock ring
2. Piston pin lock ring installer

Figure 3-47. Removing Piston Pin Lock Ring

NOTE

To avoid damage to piston or cylinder base studs, use PISTON
SUPPORT PLATE (Part No. HD-42322) to secure piston in
place while removing piston pin.

Remove piston pin. Since pin is a loose fit in piston, pin
should easily slide out. If pin is difficult to remove, use

PISTON PIN REMOVER (Part No. HD-42320-A), as fol-
lows:

See

Figure 3-48

. Remove acorn nut and spacer (1)

from rod end of tool.

Slide rod end through piston pin. Install spacer and
acorn nut on end of rod.

Position rubber coated tips (2) of tool on flat on each
side of piston pin bore.

Hold tool body (3) and turn handle (4) clockwise until
piston pin is pulled free of bore.

Remove piston from connecting rod. Be sure to hold con-
necting rod shank upright to prevent it from striking
crankcase.

10. Place a 3.0 in (76.2 mm) length of 1.0 in (25.4 mm) ID

foam-type water pipe insulation around each connecting
rod to prevent damage.

11. Mark each pin boss with either an "F" or an "R" to indicate

front or rear cylinder, respectively.

12. Spread piston rings outward until they clear grooves in

piston and lift off.

sm03431

1. Acorn nut and spacer
2. Rubber coated tip (2)
3. Tool body
4. Handle

Figure 3-48. Removing Piston Pin with HD-42320-A Piston

Pin Remover

HOME

2013 Sportster Service: Engine 3-55

3.14

CYLINDER HEAD

DISASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

See

Figure 3-49

. Clamp VALVE SPRING COMPRESSOR

(Part No. HD-34736-B) in vise and compress valve spring.

See

Figure 3-50

. Remove valve collar retainers (7), upper

valve spring collar (6) and valve spring (5). Mark valve
collar retainers for reassembly in original positions.

Use a fine tooth file to remove any burrs on the valve stem
at the retainer groove. Mark valve to match with cylinder
head.

Remove valve (1), and valve seal (2) and lower valve
spring collar assembly (4) by hand. No special tools are
required to remove valve seal and lower valve spring collar
assembly.

sm00134

Figure 3-49. Valve Spring Compressor

sm06922

1. Valve
2. Valve seat
3. Valve guide
4. Valve seal and lower spring collar
5. Spring
6. Upper valve spring collar
7. Collar retainer

Figure 3-50. Cylinder Head

CLEANING AND INSPECTION

TOOL NAME

PART NUMBER

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

VALVE SPRING TESTER

HD-96796-47

Cylinder Heads

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)

Bead blast or scrape carbon from head and valve ports.
Be careful to avoid scratching or nicking cylinder head-to-
cylinder joint faces. Blow off loosened carbon or dirt with
compressed air.

HOME

3-56 2013 Sportster Service: Engine

Soak

cylinder

head

aluminum-compatible

cleaner/solvent to loosen carbon deposits.

Wash all parts in non-flammable solvent, followed by a
thorough washing with hot, soapy water.

Blow out oil passages in head. Be sure they are free of
sludge and carbon particles.

Remove loosened carbon from valve head and valve stem
using a wire wheel. Never use a file or other hardened
tool which could scratch or nick valve.

Polish valve stem with very fine emery cloth or steel wool.

See

Figure 3-51

. Check head gasket surface on head for

flatness. Machine or replace any head which exceeds
SERVICE WEAR LIMIT of 0.006 in (0.152 mm).

sm01512a

Figure 3-51. Gasket Surface: Flat Within 0.006 in (0.152

mm)

Rocker Arm Assemblies

Check each rocker arm at pad end and pushrod end for
uneven wear or pitting. Replace rocker arm if either condi-
tion exists.

NOTE

Most of the wear in rocker arm shafts and bores results from
the up and down movement of the pushrods and valves.
Therefore, the following measurements should be taken top-
to-bottom on rocker arm shafts and bores.

See

Figure 3-52

. Measure and record rocker arm shaft

diameter at the positions where rocker arm bushings ride
and where shaft fits in inner rocker cover.

sm01514a

Figure 3-52. Measuring Rocker Arm Shaft Diameter at

Bushing Position (top) and Cover Position (bottom)

Measure and record rocker arm shaft bore diameters.

See

Figure 3-53

. Measure rocker arm shaft bore in

inner rocker cover.

See

Figure 3-54

. Measure rocker arm bushing inner

diameter.

Check clearances and measurements obtained in step 3
against specifications in

3.2 SPECIFICATIONS

. Repair

or replace parts exceeding Service Wear Limits. If rocker
arm bushings require replacement, see

3.14 CYLINDER

HEAD, Replacing Rocker Arm Bushings

See

Figure 3-55

. Assemble rocker arms and rocker arm

shafts into inner rocker cover.

Check end play of rocker arm with feeler gauge. Replace
rocker arm or inner rocker cover or both if end play
exceeds 0.025 in (0.635 mm).

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2013 Sportster Service: Engine 3-57

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Figure 3-53. Measuring Rocker Arm Shaft Bore Diameter

in Inner Rocker Cover

sm01516a

Figure 3-54. Measuring Rocker Arm Bushing Inner

Diameter

sm01518

1. Inner rocker cover
2. Rocker arm shaft (2)
3. Rocker arm (2)

Figure 3-55. Assembling Inner Rocker Cover (typical)

Valves

Replace the valve if there is evidence of burning or
cracking.

Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if necessary.

Inspect for burrs around the valve stem retainer groove.
Remove burrs with a fine tooth file if found.

Valve heads should have a seating surface width of 0.040-
0.062 in (1.02-1.57 mm), and should be free of pit marks
and burn spots. The color of carbon on exhaust valves
should be black or dark brown. White or light buff carbon
indicates excessive heat and burning.

Valve Seats

NOTE

Valve seats are subject to wear, pitting, and burning. Resurface
valve seats after finishing valves.

Inspect valve seats for cracking, chipping or burning.
Replace valve seats if necessary.

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3-58 2013 Sportster Service: Engine

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Figure 3-56. Measuring Valve Stem Protrusion

See

Figure 3-56

. Check valve seats for recession by

measuring valve stem protrusion.

Wipe valve seats and valve faces clean. Insert valve
into valve guide.

Measure valve stem protrusion from end of valve stem
to machined surface of head upon which the lower
valve collar sits, as shown. If valve stem protrudes
more than 2.082 in (52.883 mm), replace valve seat
or cylinder head.

NOTE

If the valve seat is loose or is not fully seated in the head, seat
movement will prevent the proper transfer of heat from the
valve. The valve seat surface must be flush with (or below) the
head surface. See

3.2 SPECIFICATIONS

for valve seat-to-

cylinder head fit.

Valve Guides

Clean valve guides by lightly honing with VALVE GUIDE
HONE (Part No. B-45525).

Scrub valve guides with VALVE GUIDE CLEANING
BRUSH (Part No. HD-34751) and hot soapy water.

Measure valve stem outer diameter and valve guide inner
diameter. Replace if the guides do not match specifica-
tions. See

3.2 SPECIFICATIONS

Valve Springs

Inspect valve springs for damaged or discolored coils.

See

Figure 3-57

. Measure free length of each spring. Refer

Table 3-28

Test compression force of spring using VALVE SPRING
TESTER (Part No. HD-96796-47). Refer to

Table 3-28

Replace as necessary.

sm01520

Figure 3-57. Checking Spring Free Length

Table 3-28. Valve Spring Specifications

METRIC

U.S.

SPRING

59.1 mm

2.325 in

Length (min)

1321 N @ 33.02 mm

297 lb @ 1.300 in

Compression (min)

1455 N @ 33.02 mm

327 lb @ 1.300 in

Compression (max)

Spark Plug Threads

Inspect spark plug threads for damage. If threads in cylinder
head are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.

Pushrods

Examine pushrods, particularly the ball ends. Replace any rods
that are bent, worn, discolored or damaged.

REPLACING ROCKER ARM BUSHINGS

TOOL NAME

PART NUMBER

ROCKER ARM BUSHING REAMER

HD-94804-57

See

Figure 3-58

. To replace worn bushings, press or drive

them from the rocker arm. If bushing is difficult to remove,
turn a 9/16-18 tap into bushing. From opposite side of
rocker arm, press out bushing and tap using a discarded
rocker arm shaft.

Press replacement bushing into rocker arm, flush with
rocker arm end, and split portion of bushing towards top
of rocker arm.

Using remaining old bushing as a pilot, line ream

new

bushing with ROCKER ARM BUSHING REAMER (Part
No. HD-94804-57).

Repeat for other end of rocker arm.

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Figure 3-58. Replacing Rocker Arm Bushings

REPLACING VALVE GUIDES

TOOL NAME

PART NUMBER

VALVE GUIDE REAMER

B-45523

VALVE GUIDE REMOVER/INSTALLER

B-45524

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER HEAD SUPPORT STAND

HD-39782-A

CYLINDER HEAD HOLDING FIXTURE

HD-39786

REAMER T-HANDLE

HD-39847

REAMER LUBRICANT

HD-39964

Replace valve guides before grinding valve seats. It is the valve
stem bore in valve guide that determines valve seat grinding
location. If valve stems and/or valve guides are worn beyond
service wear limits, install new parts. Refer to

Table 3-29

Removal

NOTES

•

Always use cylinder head support stand. Misalignment
during valve guide replacement will cause damage to cyl-
inder head valve guide bore.

•

Lock ring is present on OEM intake and exhaust valve
guides on XR 1200X only.

See

Figure 3-59

. Prepare cylinder head for valve guide

replacement.

XR 1200X:

Remove and discard lock ring from valve

guide groove.

Insert sleeve of intake (4 or 6) or exhaust (5 or 7) seat
adapter into tube at top of CYLINDER HEAD SUP-
PORT STAND (Part No. HD-39782-A) (3).

Position cylinder head so that valve seat is centered
on seat adapter.

NOTE

Do not press out the valve guide from the bottom of the cylinder
head. Excessive carbon buildup prevents a proper interference
fit for valve guides.

See

Figure 3-60

. At top of the cylinder head, insert VALVE

GUIDE REMOVER/INSTALLER (Part No. B-45524) (1)
into valve guide bore until tool shoulder contacts end of
valve guide.

NOTE

See

Figure 3-59

. Installer sleeve (2) is not used for removal of

valve guide.

Center VALVE GUIDE REMOVER/INSTALLER under ram
(3) of press. Apply pressure until valve guide drops free
of cylinder head. Discard valve guide.

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3-60 2013 Sportster Service: Engine

Harley Davidson 2013 Sportster Models. Service Manual - page 36