Harley Davidson 2013 Sportster Models. Service Manual

sm01555

1. Front
2. Rear
3. Piston pin

Figure 3-89. Position Ring End Gaps at Arrows

See

Figure 3-90

. Install PISTON SUPPORT PLATE (Part

No. HD-42322) as shown. Rotate crankshaft to rest piston
on support plate.

See

Figure 3-91

. Compress the piston rings using PISTON

RING COMPRESSOR (Part No. HD-96333-51E).

10. Gently slide cylinder over cylinder base studs and piston

crown, resting it on the top of the ring compressor band
as shown.

11. Push the cylinder down with a firm, quick motion until the

bottom of the cylinder bore slides below the piston ring
area.

12. Remove the piston ring compressor and piston support

plate, and push the cylinder all the way down onto the
crankcase cylinder deck.

13. Repeat for other piston and cylinder.

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Figure 3-90. Piston Support Plate

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Figure 3-91. Installing Cylinder Over Piston

TAPPET COVERS, PUSHROD COVERS AND
PUSHRODS

TORQUE VALUE

FASTENER

10.2-13.6 Nm

90-120

in-lbs

Tappet cover fastener

See

Figure 3-93

. If anti-rotation devices (10) and tappets

(11) have been removed, install the tappets. See

3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets

HOME

2013 Sportster Service: Engine 3-77

See

Figure 3-92

. Orient tabs of the front (1) and rear (2)

tappet covers to the front and rear cylinders.

See

Figure 3-93

. Install tappet covers (7) with

new

gaskets

(8). Secure with screws (5) and washers (6). Tighten to
90-120

in-lbs

(10.2-13.6 Nm).

Install

new

O-rings (3) in recesses in tappet covers. Press

pushrod covers (2) into O-rings.

Identify pushrod location by its color and length. Refer to

Table 3-33

Slide intake and exhaust pushrods (4) down inside pushrod
covers until they rest on seat at top of tappet (11).

Table 3-33. Pushrod Specifications

LENGTH

COLOR

BAND

POSITION

27.295

10.746

Orange

Intake

27.432

10.800

Purple

Exhaust

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1. Front cylinder
2. Rear cylinder

Figure 3-92. Tappet Cover Orientation

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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 3-93. Middle Valve Train Components

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3-78 2013 Sportster Service: Engine

CYLINDER HEAD

TORQUE VALUE

FASTENER

11-14 Nm

96-120

in-lbs

Cylinder headbolts, 1st torque

18-20 Nm

13-15 ft-lbs

Cylinder headbolts, final
torque

11-14 Nm

96-120

in-lbs

Cylinder headbolts, 1st torque

18-20 Nm

13-15 ft-lbs

Cylinder headbolts, final
torque

NOTES

•

Install the pushrod covers and lower cover retainers before
installing cylinder heads. See

3.16 TOP END OVERHAUL:

ASSEMBLY, Tappet Covers, Pushrod Covers and Push-
rods

•

Thoroughly clean and lubricate threads of cylinder head
screws before installation. Friction caused by dirt and
grime will result in a false torque indication.

Coat mating surfaces of cylinder base studs and headbolts
with parts cleaning solution.

Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head screw
onto its mating cylinder stud.

Remove headbolts from studs. Wipe or blow dry thread
surfaces.

Thoroughly clean and dry gasket surfaces of cylinder and
cylinder head.

NOTE

XR 1200X: See

Figure 3-94

. The cylinder head gasket has

metal patches (2) that must be installed against the cylinder
head. When installing the gasket on the cylinder, be sure the
words "THIS SIDE UP" (1) and the metal patches (2) are visible.

See

Figure 3-95

. Install a

new

head gasket to cylinder.

Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.

NOTE

Only oil film must remain on the cylinder head screw surfaces.
Too much oil will pool in the head screw sleeve preventing full
thread engagement.

Lightly coat threads, underside of flange and bottom face
of cylinder headbolts in clean Harley-Davidson 20W50
engine oil. Wipe off excess oil.

Start cylinder headbolts onto cylinder studs, two short bolts
on left side of engine, two long bolts on right. Tighten all
bolts only finger-tight at this time.

NOTE

The procedure for tightening the head screws is critical to
proper distribution of pressure over gasket area. It prevents
gasket leaks, stud failure and head and cylinder distortion.

See

Figure 3-96

and

Figure 3-97

. In sequence, tighten

headbolts in the following steps:

Tighten each bolt to 96-120

in-lbs

(11-14 Nm).

Tighten each bolt to 13-15 ft-lbs (18-20 Nm).

Loosen all bolts.

10. After headbolts are loosened from initial torque, tighten

bolts in three stages. Tighten in sequence:

Tighten each bolt to 96-120

in-lbs

(11-14 Nm).

Tighten each bolt to 13-15 ft-lbs (18-20 Nm).

See

Figure 3-98

. Mark cylinder head and headbolt

shoulder with a line (1).

Tighten each bolt an additional 85-95 degrees (2).

11.

XR 1200X:

Install Precision Cooling oil lines. See

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

sm05483c

1. THIS SIDE UP
2. Metal patches

Figure 3-94. Cylinder Head Gasket: XR 1200X

HOME

2013 Sportster Service: Engine 3-79

ROCKER COVERS

TORQUE VALUE

FASTENER

24.4-29.8 Nm

18-22 ft-lbs

Rocker cover, inner, large bolt

15.3-17.5 Nm

135-155

in-lbs

Rocker cover, inner, small bolt

15.3-17.5 Nm

135-155

in-lbs

Rocker cover, inner, screw

4.0-6.2 Nm

35-55

in-lbs

Breather screw: XL Models

13.5-19.0 Nm

120-168

in-lbs

Rocker cover, outer, screw

Inner Cover

For each cylinder, rotate crankshaft so that the lifters are
on the base circle of the cams.

Install

new

gasket (1) with FRONT HEAD facing up on

the front head and REAR HEAD facing up on the rear
head.

XL Models:

See

Figure 3-101

XR 1200X:

See

Figure 3-102

Install the inner rocker cover assembly (2) (with rocker
arms and shafts). Fit the ends of the pushrods in the rocker
arm sockets.

NOTE

To avoid damage to pushrods or rocker arms, do not rotate
crankshaft until both pushrods can be turned with fingers.

Install and finger tighten all fasteners (3, 5, 4) one turn at
a time.

See

Figure 3-99

. Tighten the fasteners in sequence:

Tighten the four large bolts (1, 2, 3, 4) and then re-
tighten the first fastener (5) to 18-22 ft-lbs (24.4-29.8
Nm).

Tighten the three small bolts (6, 7, 8) to 135-155

in-lbs

(15.3-17.5 Nm).

Tighten the two screws (9, 10) to 135-155

in-lbs

(15.3-17.5 Nm).

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Figure 3-99. Inner Rocker Cover Torque Sequence

Breather: XL Models

Identify breather location for front and rear cylinders.

See

Figure 3-101

. Install breather (7) with

new

breather

seal (6).

Install screw (8). Tighten to 35-55

in-lbs

(4.0-6.2 Nm).

Breather: XR 1200X

See

Figure 3-102

. Inspect and replace the umbrella check

valve (8) if necessary.

Install a

new

O-ring (6) on the breather assembly (7).

Install breather in cavity.

Outer Cover

NOTES

•

XL Models: See

Figure 3-101

•

XR 1200X: See

Figure 3-102

Install

new

gaskets (9, 10) on the inner rocker cover.

Install outer rocker cover (11) on inner rocker cover. Install
fasteners (13) with captive washers and

new

sealing

washers (12).

See

Figure 3-100

. Tighten fasteners (1, 2, 3, 4) in

sequence and then re-tighten the first fastener (5) to 120-
168

in-lbs

(13.5-19.0 Nm).

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Figure 3-100. Outer Cover Torque Sequence

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2013 Sportster Service: Engine 3-81

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1. Gasket
2. Inner rocker cover
3. Large bolts (4)
4. Small bolts (3)
5. Screws (2)
6. Breather seal
7. Breather
8. Screw
9. Gasket
10. Cover gasket
11. Outer rocker cover
12. Sealing washer (4)
13. Fastener (4)

Figure 3-101. Rocker Cover: XL Models

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1. Gasket
2. Inner rocker cover
3. Large bolts (4)
4. Screws (2)
5. Small bolts (3)
6. O-ring
7. Breather
8. Umbrella valve
9. Gasket
10. Gasket
11. Outer rocker cover
12. Sealing washer (4)
13. Fastener (4)

Figure 3-102. Rocker Cover: XR 1200X

HOME

3-82 2013 Sportster Service: Engine

ASSEMBLING MOTORCYCLE AFTER TOP
END REPAIR

TORQUE VALUE

FASTENER

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link, upper front,
frame bracket mounting screw

33.9-47.5 Nm

25-35 ft-lbs

Stabilizer link, lower front,
frame bracket mounting screw

20.4-27.1 Nm

15-20 ft-lbs

Fuel tank mounting screw

See

Figure 3-103

. Install upper front stabilizer link and

frame bracket:

Install upper frame bracket (3) with upper stabilizer
link (2), horn bracket (9) (models with front mounted
horn), screws (5) and washers (8). Tighten to 25-35
ft-lbs (33.9-47.5 Nm).

Install screw (4) securing stabilizer link to engine
bracket (1). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

Install induction module assembly. See

4.8 INDUCTION

MODULE: XL MODELS

4.9 INDUCTION MODULE: XR

1200X

Install the following connectors into the induction module:

TPS [88].

IAC [87].

TMAP sensor [80].

Fuel injector connectors [84], [85].

Install air cleaner assembly:

XL Models except XL 1200V:

Install backplate, air

filter and air cleaner cover. See

4.3 AIR CLEANER

ASSEMBLY, XL Models except XL 1200V

XL 1200V:

Install backplate, air filter and air cleaner

cover. See

4.3 AIR CLEANER ASSEMBLY, XL

1200V

XR 1200X:

Install air box assembly and connect

crankcase vent hoses. See

4.3 AIR CLEANER

ASSEMBLY, XR 1200X

EVAP Controlled Models:

Install EVAP purge hose

on induction module. See

4.20 EVAPORATIVE

EMISSIONS CONTROL

Install horn.

Front Mount:

See

6.32 HORN, Replacement: Front

Mount

Side Mount:

See

6.32 HORN, Replacement: Side

Mount

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)

Install fuel tank.

Tighten to 15-20 ft-lbs (20.4-27.1 Nm).

Attach quick-connect fitting on fuel line to fuel tank
fitting.

Gently tug on quick-connect fitting to verify that it is
securely locked in place. See

4.4 FUEL TANK: XL

MODELS

4.5 FUEL TANK: XR 1200X

Install exhaust pipes and mufflers. Plug in O2 sensor
connectors [137], [138]. See

4.13 EXHAUST SYSTEM:

XL MODELS

4.14 EXHAUST SYSTEM: XR 1200X

Connect spark plug cables to spark plugs.

Install main fuse.

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)

10. Install seat.

sm03404

1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lockwasher (2)
8. Washer (2)
9. Horn bracket (models with front mounted horn)

Figure 3-103. Upper Front Stabilizer Link Assembly (typical)

HOME

2013 Sportster Service: Engine 3-83

3.17

BOTTOM END OVERHAUL: DISASSEMBLY

GENERAL

This section describes disassembling the bottom end of the
engine. If engine overhaul requires disassembly of crankcases,
remove engine from vehicle. See

3.10 REMOVING ENGINE

FROM CHASSIS

Then disassemble top end of engine. See

3.13 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

and

3.13 TOP

END OVERHAUL: DISASSEMBLY, Cylinder and Piston

Thoroughly clean area around gearcase cover and tappets.
Blow loose dirt from crankcase with low pressure compressed
air.

The oil pump design and function differs between XL models
and the XR 1200X. See

3.6 ENGINE LUBRICATION SYSTEM

OIL PUMP: XL MODELS

Remove oil pump feed and return hoses. Mark hoses for
later installation. Discard hose clamps.

See

Figure 3-104

. Carefully remove two screws (2) that

secure pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket.

If oil pump requires repair, see

3.20 OIL PUMP: XL

MODELS

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1. Oil pump
2. Screw w/ washer (2)
3. Screw, Torx (2)
4. Gasket

Figure 3-104. Oil Pump: XL Models

TAPPETS

See

Figure 3-105

. Remove screw (1).

Remove anti-rotation device (2). Tag anti-rotation device
for location (front/rear cylinder) as it is removed.

Remove tappet (3). Tag tappet for location (front/rear cyl-
inder) and function (intake/exhaust) as it is removed. This
will simplify installation.

Repeat previous steps for other cylinder.

Place tappets in clean plastic bags to keep out dust, dirt
and debris.

sm03422a

1. Screw (2)
2. Anti-rotation device (2)
3. Tappet (4)
4. Right crankcase

Figure 3-105. Tappet Components

CAM GEAR END PLAY

NOTE

Gauge cam gear end play with the tappets removed.

Rotate the crankshaft until the lobe of the cam gear is
pointing toward the tappet guide bore.

With a flat blade screwdriver, gently pry the cam gear
toward the gearcase cover.

Gauge the gap between the case bushing and the cam
gear shaft thrust face.

Compare the gauge size to the cam gear end play specific-
ations. Refer to

Table 3-14

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3-84 2013 Sportster Service: Engine

GEARCASE COVER AND CAM GEARS: XL
MODELS

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)

Remove any parts that will interfere with gearcase disas-
sembly.

Remove inner rocker cover to remove valve spring pres-
sure from the camshafts. See

3.22 BOTTOM END

OVERHAUL: ASSEMBLY, Cam Gears and Gearcase
Cover: XL Models

Measure cam gear end play and record measurements.
See

3.17 BOTTOM END OVERHAUL: DISASSEMBLY,

Cam Gear End Play

Place a pan under gearcase to collect oil.

NOTE

Never pry cover off. Tap lightly with a rawhide hammer.

See

Figure 3-106

. Remove cover screws (1) and cover

(2). Discard old gasket (3).

Remove cam gears (4, 5, 6 and 7). Mark each component
for installation.

NOTE

Nut is secured by LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) on the nut threads.

Remove nut (8). Slide pinion gear (9) and oil pump drive
gear (10) off pinion shaft.

sm06924

1. Fastener
2. Cover
3. Gasket
4. Rear exhaust cam
5. Rear intake cam
6. Front intake cam
7. Front exhaust cam
8. Nut
9. Pinion gear
10. Oil pump drive gear
11. Shaft key

Figure 3-106. Gearcase Cover and Cam Gears

OIL PUMP HOUSING/GEARCASE COVER
AND CAM GEARS: XR 1200X

The oil pump is integrated into the gearcase cover. Oil pump
rotors can be removed with gearcase cover in place. It is not
necessary to remove the oil pump rotors to remove the gear-
case cover.

Remove any parts that will interfere with gearcase disas-
sembly.

Remove inner rocker cover to remove valve spring pres-
sure from the camshafts. See

3.13 TOP END OVERHAUL:

DISASSEMBLY, General

Measure cam gear end play and record measurements.
See

3.17 BOTTOM END OVERHAUL: DISASSEMBLY,

Cam Gear End Play

Place a pan under gearcase to collect oil.

NOTE

Never pry cover off. Tap lightly with a rawhide hammer.

See

Figure 3-107

. Remove cover screws (1) and remove

cover (2). Discard old gasket.

HOME

2013 Sportster Service: Engine 3-85

See

Figure 3-108

. Remove rigid lines (1) and vent hose

(2) from gearcase cover. Mark lines and hoses for later
installation. Discard hose clamps. See

3.12 PRECISION

COOLING SYSTEM: XR 1200X, Oil Pump Lines

Remove two check valve housing screws (3).

Remove six screws (4) and remove oil pump cover (5).
Discard O-rings.

Remove three fasteners (6). Loosely install oil pump cover
to prevent the gerotors from falling out unexpectedly.

NOTE

Never pry gearcase cover off. Tap lightly with a rawhide
hammer.

10. Carefully remove gearcase cover. Discard old gasket.

NOTE

Repair the oil pump if required. See

3.21 OIL PUMP: XR

1200X

11. See

Figure 3-109

. Remove cam gears (1, 2, 3, and 4).

Carefully mark each component to verify correct installa-
tion.

NOTE

Nut (5) is secured by LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red).

12. Remove nut (5). Slide pinion gear (6) and spacer (7) off

pinion shaft.

13. Remove oil pump cover. Mark rotors with a permanent

marker to identify outer surfaces. Remove rotors from
housing.

sm05003a

1. Fastener (9)
2. Cover

Figure 3-107. Oil Pump Cover: XR 1200X

sm05004a

1. Rigid lines
2. Vent hose
3. Check valve screws (2)
4. Oil pump cover screw (6)
5. Oil pump cover
6. Gearcase cover fastener (3)

Figure 3-108. Gearcase Cover and Oil Pump: XR 1200X

sm05008a

1. Rear exhaust cam gear
2. Rear intake cam gear
3. Front intake cam gear
4. Front exhaust cam gear
5. Nut
6. Pinion gear
7. Spacer

Figure 3-109. Cam Gears: XR 1200X

CRANKCASE

Split Crankcase

Remove clutch and primary drive components. See

5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS

Remove starter motor. See

6.10 STARTER

Mount crankcase assembly in engine stand. Position
crankcase so that it is tilted at a 45 degree angle, right
side down.

HOME

3-86 2013 Sportster Service: Engine

Do not rotate right crankcase half in engine stand such
that flywheel sprocket shaft is facing down. The flywheel
assembly can fall out, resulting in parts damage or mod-
erate injury. (00553b)

NOTE

XR 1200X: See

Figure 3-110

. The fastener between the cylin-

ders is a double headed bolt (2).

Remove 11 long fasteners (1, 2) and four short fasteners
(3) from left side of crankcase assembly.

Remove two fasteners (4) from right side of crankcase
assembly.

sm03405a

1. Long fastener: left side
2. XR 1200X: double-headed long fastener
3. Short fastener: left side
4. Long fastener: right side

Figure 3-110. Crankcase Fasteners

See

Figure 3-111

. Tap crankcase gently with rawhide

mallet to loosen and separate the halves. Remove left
crankcase assembly with transmission.

NOTE

Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.

See

Figure 3-112

. Remove the flywheel assembly from

right crankcase.

Remove transmission assembly from left crankcase. See

5.9 TRANSMISSION REMOVAL AND DISASSEMBLY

sm06548

Figure 3-111. Separating Crankcase Halves

sm06549

Figure 3-112. Removing Flywheels from Right Crankcase

Piston Oil Jets

See

Figure 3-113

. Remove two TORX screws (3) from

each piston oil jet assembly (2) to free piston oil jets from
right crankcase (1).

Remove piston oil jets and gaskets (4) from right crank-
case. Discard gaskets.

XR 1200X:

Remove three screws (6) and oil deflector

plate (5).

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2013 Sportster Service: Engine 3-87

sm01596a

1. Right crankcase
2. Piston oil jet (2)
3. Screw (4)
4. Gasket (2)
5. Oil deflector plate (XR 1200X)
6. Screw (3) (XR 1200X)

Figure 3-113. Piston Oil Jet Assemblies

Removing Cylinder Base Studs

If cylinder base studs require replacement, proceed as follows.

Thread a 3/8-16 nut onto cylinder base stud.

Thread a second nut onto stud until it contacts the first
nut.

Tighten nuts against each other.

Placing wrench on first (lower) nut installed, remove stud
from cylinder deck.

Loosen nuts and remove from cylinder base stud.

HOME

3-88 2013 Sportster Service: Engine

3.18

GEARCASE: XL MODELS

BUSHING INSPECTION AND REMOVAL: XL
ONLY

TOOL NAME

PART NUMBER

BUSHING AND BEARING PULLER

HD-95760-69A

NOTE

The camshaft and pinion gear shafts are supported by bushings
in both the cover and the crankcase.

See

Figure 3-114

. Measure each bushing and its corres-

ponding cam gear shaft or pinion gear shaft. Replace
bushings that exceed service wear limits. Refer to

Table 3-34

See

Figure 3-115

. Use BUSHING AND BEARING PULLER

(Part No. HD-95760-69A) to remove bushings from gear-
case cover and crankcase.

sm06923

1. Rear intake
2. Front intake
3. Pinion
4. Rear exhaust
5. Front exhaust

Figure 3-114. Cam and Pinion Bushings

Table 3-34. Cam and Pinion Shaft Specifications

SERVICE WEAR

LIMIT

CORRECT CLEARANCE

SHAFT

0.08

0.003

0.018-0.056

0.0007-0.0022

Cam

0.13

0.005

0.058-0.109

0.0023-0.0043

Pinion

sm01480

Figure 3-115. Removing Cam Bushing from Gearcase

Cover

BUSHING INSTALLATION: XL ONLY

NOTE

Installing and reaming crankcase and gearcase cover bushings
can alter the center distances between mating gears. Incorrect
spacing can damage gears and increase gear noise.

Cam Gear Bushings in Right Crankcase

See

Figure 3-116

. Each cam gear bushing installed in right

crankcase must be positioned with its oiling slot at exact top
of bore (12 o'clock position).

Using an arbor press, install each bushing in crankcase
bore until bushing shoulder contacts crankcase boss.

Ream the

new

bushing to size after installation. See

3.18 GEARCASE: XL MODELS, Bushing Reaming: XL
Only

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2013 Sportster Service: Engine 3-89

sm01481a

1. Cam gear bushing
2. Slot at top
3. Right crankcase

Figure 3-116. Cam Gear Bushing Installed in Crankcase

Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover

Using an arbor press, install each bushing in its gearcase
cover bore so that bushing shoulder contacts cover boss.
There is no need to orient these particular bushings in any
specific position of rotation within gearcase cover bores.

Line-ream the

new

bushing to correct size after installation.

See

3.18 GEARCASE: XL MODELS, Bushing Reaming:

XL Only

Rear Intake Cam Gear Bushing in Gearcase
Cover

Rear intake cam gear bushing must be installed in its gearcase
cover bore using an arbor press. The bushing must be oriented
in a specific position of rotation within the cover bore.

See

Figure 3-117

. Position bushing (1) over bore of gear-

case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.

Line-ream the

new

bushing to correct size after installation.

See

3.18 GEARCASE: XL MODELS, Bushing Reaming:

XL Only

Pinion Shaft Bushing in Gearcase Cover

Using an arbor press, install pinion shaft bushing in gear-
case cover flush with cover boss. This bushing requires
no specific orientation.

See

Figure 3-118

. The replacement bushing must be

secured from rotation by installation of a dowel pin. Drill
a No. 31 hole, 0.281 in (7.14 mm) deep, at top side of boss
(side toward top of gearcase cover). Center drill bit so hole
is drilled half in bushing and half in cover.

Drive a

new

dowel pin no more than 0.020 in (0.51 mm)

below the bushing face. Carefully peen edges of hole to
lock the pin in place.

Line-ream the

new

bushing to correct size after installation.

See

3.18 GEARCASE: XL MODELS, Bushing Reaming:

XL Only

sm01482a

1. Rear intake cam gear bushing
2. Gearcase cover
3. Cam bushing slot
4. Gearcase cover slot

Figure 3-117. Rear Intake Cam Gear Bushing Installed in

Gearcase Cover

sm01483

Figure 3-118. Drilling Pinion Bushing Dowel Pin Hole in

Gearcase Cover

BUSHING REAMING: XL ONLY

TOOL NAME

PART NUMBER

CRANKSHAFT BUSHING PLATE
PILOT

HD-38871

REAR INTAKE CAM GEAR BUSHING
REAMER

HD-94803-67

REAMER

HD-94812-1

PILOT

HD-94812-87

NOTES

•

Installing and reaming crankcase and gearcase cover
bushings can alter the center distances between mating

HOME

3-90 2013 Sportster Service: Engine

gears. Incorrect spacing can damage gears and increase
gear noise.

•

Bushings in right crankcase serve as pilots for reaming
gearcase cover bushings and must, therefore, be reamed
to size first.

•

After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.

Cam Gear Bushings in Right Crankcase

Separate two halves of crankcase, if not already done.
Place right crankcase on flat surface with gearcase side
up.

See

Figure 3-119

. Position CRANKSHAFT BUSHING

PLATE PILOT (Part No. HD-38871) onto gearcase side
of crankcase. The upper right and lower left indexing holes
in pilot must be placed over dowels in crankcase. Insert
two bolts (supplied with pilot) through two remaining holes
in pilot, and into threaded holes of crankcase. Tighten
bolts securely.

Insert a standard 11/16 reamer through pilot hole and into
bushing while turning reamer clockwise. Continue turning
reamer clockwise through bushing until smooth shank of
reamer passes through hole in pilot.

Detach reamer from handle. Pull reamer out opposite side
of crankcase.

Thoroughly clean right crankcase, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

sm01484a

1. Camshaft bushing reamer pilot (Part No. HD-

38871)

2. Standard 11/16 reamer
3. Reamer handle

Figure 3-119. Reaming Cam Gear Bushing in Right

Crankcase

Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover

NOTE

Newly installed cam gear bushings must be line-reamed to
establish correct clearance and to produce perfect alignment.
Use the right crankcase as a pilot for the reamer. If crankcase
halves are not separated, use a spare right crankcase to per-
form the following line-reaming procedures.

Bushings to be reamed must be installed in gearcase cover
as described in

3.18 GEARCASE: XL MODELS, Bushing

Installation: XL Only

. Attach gearcase cover to right

crankcase, which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.

Insert a standard 11/16 reamer through the previously
reamed cam gear bushing in right crankcase, which is in
line with one of the bushings to be reamed in gearcase
cover.

Turn reamer clockwise through bushing in cover until
reamer bottoms. Then give reamer one complete clockwise
turn to size the bushing. Continue turning reamer clockwise
while extracting reamer from bushing.

Repeat two previous steps for remaining two cam gear
bushings (except rear intake bushing) in gearcase cover,
if required.

Separate gearcase cover from right crankcase. Inspect
bushings for proper cam gear shaft fit. Repeat line reaming
operation if necessary.

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2013 Sportster Service: Engine 3-91

Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

Rear Intake Cam Gear Bushing in Gearcase
Cover

NOTE

Rear intake cam gear bushing must be installed in gear-
case cover as described in

3.18 GEARCASE: XL

MODELS, Bushing Installation: XL Only

Identify the previously reamed rear intake cam gear
bushing in right crankcase, which has been disassembled
from left crankcase. Insert the shank end of REAR INTAKE
CAM GEAR BUSHING REAMER (Part No. HD-94803-67)
through gearcase side of this bushing.

With reamer inserted into bushing in right crankcase,
attach gearcase cover to right crankcase, securing with a
minimum of three mounting screws.

Turn reamer clockwise through bushing in gearcase cover
until reamer bottoms. Then give reamer one complete
clockwise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.

Separate gearcase cover from right crankcase. Inspect
bushing for proper cam gear shaft fit. Repeat line reaming
operation if necessary.

Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.

Pinion Shaft Bushing in Gearcase Cover

NOTE

Ream a new pinion shaft bushing in the gearcase cover with
the right crankcase and the PILOT (Part No. HD-94812-87) as

pilots for the reamer. If the crankcase halves are not separated,
use a spare right crankcase to line ream the bushing.

Pinion shaft bushing must be installed in gearcase cover
as described in

3.18 GEARCASE: XL MODELS, Bushing

Installation: XL Only

. Attach gearcase cover to right

crankcase, which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.

See

Figure 3-120

. Install a PILOT (Part No. HD-94812-

87) into right crankcase roller race. Insert REAMER (Part
No. HD-94812-1) through the pilot.

Separate gearcase cover from right crankcase. Inspect
bushing for proper pinion shaft fit. Repeat line reaming
operation if necessary.

Remove pilot from right crankcase roller race. Thoroughly
clean gearcase cover, removing all metal chips/shavings.
Blow out all bushing bores and oil passages using low
pressure compressed air.

sm01485a

Figure 3-120. Line Reaming Pinion Shaft Bushing

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3-92 2013 Sportster Service: Engine

Harley Davidson 2013 Sportster Models. Service Manual - page 38