2013 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

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2013 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

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DESCRIPTION:

2013 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL

This service manual has been prepared with the following purposes in mind:

• To acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and
  repair.
• To introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved major repair methods.

We sincerely believe that this service manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive/Transmission
6 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Compensating Sprocket
D Appendix D Conversions
E Appendix E Glossary

• Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
• For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
• For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
• A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.

TABLE OF CONTENTS:

2013 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

FOREWORD..............................................................................  7
TABLE OF CONTENTS.....................................................................  9
1. MAINTENANCE........................................................................ 23
	1.1 FASTENER TORQUE VALUES........................................................ 25
		Fastener Torque Values in this Chapter........................................ 25
	1.2 GENERAL....................................................................... 27
		Servicing a New Motorcycle.................................................... 27
		Safe Operating Maintenance.................................................... 27
		Shop Practices................................................................ 27
		Repair and Replacement Procedures............................................. 28
		Cleaning...................................................................... 29
		Tool Safety................................................................... 29
	1.3 FUEL AND OIL.................................................................. 31
		Fuel.......................................................................... 31
		Gasoline Blends............................................................... 31
		Engine Lubrication............................................................ 31
		Winter Lubrication............................................................ 32
	1.4 BULB REQUIREMENTS............................................................. 33
		Bulb Chart.................................................................... 33
	1.5 MAINTENANCE SCHEDULE.......................................................... 34
		General....................................................................... 34
	1.6 ENGINE OIL AND FILTER......................................................... 39
		Checking and Adding Oil....................................................... 39
		Changing Oil and Filter....................................................... 40
	1.7 AIR FILTER.................................................................... 43
		XL Models except XL 1200V..................................................... 43
		XL 1200V...................................................................... 43
		XR 1200X...................................................................... 44
		Cleaning Filter Element....................................................... 46
	1.8 TIRES AND WHEELS.............................................................. 47
		Air Pressure.................................................................. 47
		Tire Replacement.............................................................. 47
		Specified Tires............................................................... 48
		Wheel Bearings................................................................ 48
		Wheel Spokes.................................................................. 48
	1.9 PRIMARY CHAIN................................................................. 50
		Free Play Adjustment.......................................................... 50
	1.10 TRANSMISSION LUBRICANT....................................................... 51
		Transmission Lubrication...................................................... 51
	1.11 CLUTCH....................................................................... 53
		Adjustment.................................................................... 53
	1.12 DRIVE BELT AND SPROCKETS..................................................... 55
		General....................................................................... 55
		Cleaning...................................................................... 55
		Inspection.................................................................... 55
		Drive Belt Deflection......................................................... 56
	1.13 THROTTLE CONTROL............................................................. 59
		Cable Inspection and Lubrication.............................................. 59
		Cable Adjustment.............................................................. 59
	1.14 CABLE AND CHASSIS LUBRICATION................................................ 60
		General....................................................................... 60
		Cables and Hand Levers........................................................ 60
		Foot Shift Lever and Rear Brake Pedal......................................... 60
		Jiffy Stand................................................................... 60
		Steering Head Bearings........................................................ 60
	1.15 BRAKES....................................................................... 61
		General....................................................................... 61
		Brake Lines................................................................... 61
		Fluid Level................................................................... 61
		Troubleshooting............................................................... 63
	1.16 BRAKE PADS AND DISCS: XL MODELS.............................................. 64
		Inspection.................................................................... 64
		Brake Pad Replacement: Front.................................................. 65
		Brake Pad Replacement: Rear................................................... 68
	1.17 BRAKE PADS AND DISCS: XR 1200X............................................... 71
		Inspection.................................................................... 71
		Brake Pad Replacement: Front.................................................. 72
		Brake Pad Replacement: Rear................................................... 74
	1.18 SPARK PLUGS.................................................................. 77
		Removal....................................................................... 77
		Inspection.................................................................... 77
		Cleaning...................................................................... 77
		Installation.................................................................. 77
		Spark Plug Cable Inspection................................................... 78
	1.19 STEERING HEAD BEARINGS....................................................... 79
		Fall-Away..................................................................... 79
		Lubrication................................................................... 79
	1.20 CRITICAL FASTENERS........................................................... 80
		Inspection.................................................................... 80
	1.21 ENGINE MOUNTS AND STABILIZER LINKS........................................... 82
		Inspection.................................................................... 82
	1.22 BATTERY MAINTENANCE.......................................................... 83
		General....................................................................... 83
		Battery Disconnection and Removal............................................. 84
		Cleaning and Inspection....................................................... 85
		Voltmeter Test................................................................ 85
		Charging Battery.............................................................. 85
		Battery Installation and Connection........................................... 86
		Storage....................................................................... 87
	1.23 EXHAUST SYSTEM............................................................... 89
		Exhaust System Leak Check..................................................... 89
	1.24 WHEEL ALIGNMENT.............................................................. 90
		Wheel Alignment............................................................... 90
	1.25 SUSPENSION ADJUSTMENTS....................................................... 92
		Front Fork: XR 1200X.......................................................... 92
		Shock Absorber Preload: All Models............................................ 93
		Shock Absorber Rebound and Compression: XR 1200X.............................. 94
		Suspension Tuning: XR 1200X................................................... 94
	1.26 HEADLAMP ALIGNMENT........................................................... 96
		Headlamp Alignment............................................................ 96
		Headlamp: Adjustment.......................................................... 96
	1.27 STORAGE...................................................................... 98
		Placing in Storage............................................................ 98
		Removal From Storage.......................................................... 98
	1.28 TROUBLESHOOTING..............................................................100
		General.......................................................................100
		Engine........................................................................100
		Lubrication System............................................................101
		Electrical System.............................................................102
		Transmission..................................................................102
		Handling......................................................................102
		Brakes........................................................................102
2. CHASSIS............................................................................105
	2.1 FASTENER TORQUE VALUES........................................................107
		Fastener Torque Values in this Chapter........................................107
	2.2 SPECIFICATIONS................................................................115
		Tables........................................................................115
	2.3 VEHICLE IDENTIFICATION NUMBER (VIN)...........................................118
		Vehicle Identification Number (VIN)...........................................118
	2.4 TIRES.........................................................................120
		Removal.......................................................................120
		Cleaning, Inspection and Repair...............................................120
		Installation..................................................................120
		Checking Tire Runout..........................................................121
		Wheel Balancing...............................................................122
	2.5 WHEELS........................................................................124
		General.......................................................................124
		Wheel Bearing End Play........................................................124
		Front Wheel...................................................................125
		Rear Wheel....................................................................129
		Sealed Wheel Bearings.........................................................131
	2.6 WHEEL LACING..................................................................134
		Wheel Lacing: Angle Flange Hub................................................134
		Wheel Lacing: Straight Flange Hub, Single Hole Circle.........................135
		Wheel Lacing: Straight Flange Hub, Dual Hole Circle...........................137
	2.7 CHECKING AND TRUING WHEELS....................................................139
		Cast Wheel Runout.............................................................139
		Laced Wheel Rim Offset........................................................139
		Truing Laced Wheels...........................................................141
	2.8 FRONT BRAKE MASTER CYLINDER...................................................143
		General.......................................................................143
		Inspection....................................................................143
		Removal.......................................................................143
		Disassembly...................................................................145
		Cleaning, Inspection and Repair...............................................147
		Assembly......................................................................147
		Installation..................................................................148
	2.9 FRONT BRAKE CALIPER: XL MODELS................................................151
		Removal.......................................................................151
		Disassembly...................................................................152
		Cleaning, Inspection and Repair...............................................154
		Assembly......................................................................155
		Lubricating Front Caliper Bolt Pins and Boots.................................155
		Installing Brake Pads in Caliper..............................................156
		Installation..................................................................157
	2.10 FRONT BRAKE CALIPER: XR 1200X................................................159
		Removal.......................................................................159
		Disassembly...................................................................160
		Cleaning, Inspection and Repair...............................................161
		Assembly......................................................................162
		Installation..................................................................163
	2.11 REAR BRAKE MASTER CYLINDER: XL MODELS........................................164
		General.......................................................................164
		Inspection....................................................................164
		Removal.......................................................................164
		Disassembly...................................................................165
		Cleaning and Inspection.......................................................166
		Assembly......................................................................167
		Installation..................................................................168
	2.12 REAR BRAKE MASTER CYLINDER: XR 1200X.........................................170
		General.......................................................................170
		Inspection....................................................................170
		Removal.......................................................................170
		Disassembly...................................................................171
		Cleaning, Inspection and Repair...............................................172
		Assembly......................................................................172
		Installation..................................................................173
	2.13 REAR BRAKE MASTER CYLINDER RESERVOIR.........................................175
		Removal: XL Models............................................................175
		Installation: XL Models.......................................................176
		Removal: XR 1200X.............................................................176
		Installation: XR 1200X........................................................177
	2.14 REAR BRAKE CALIPER: XL MODELS................................................178
		Removal.......................................................................178
		Disassembly...................................................................180
		Cleaning, Inspection and Repair...............................................181
		Lubricating Rear Caliper Bolt Pins and Boots..................................181
		Assembly......................................................................182
		Installation..................................................................183
	2.15 REAR BRAKE CALIPER: XR 1200X.................................................185
		Removal.......................................................................185
		Disassembly...................................................................186
		Cleaning, Inspection and Repair...............................................188
		Assembly......................................................................188
		Installation..................................................................189
	2.16 BRAKE LINES..................................................................192
		Front Brake Line..............................................................192
		Front Brake Line Routing......................................................194
		Rear Brake Line: XL Models....................................................196
		Rear Brake Line: XR 1200X.....................................................198
	2.17 BLEEDING BRAKES..............................................................200
		General.......................................................................200
		Procedure.....................................................................200
	2.18 LEFT SIDE COVER..............................................................202
		General.......................................................................202
		Opening Left Side Cover.......................................................202
		Closing Left Side Cover.......................................................203
		Removing Left Side Cover......................................................203
		Installing Left Side Cover....................................................203
	2.19 FRONT FORK: XL MODELS........................................................204
		Changing Fork Oil: XL Models..................................................204
		Removal.......................................................................205
		Disassembly...................................................................205
		Cleaning, Inspection and Repair...............................................205
		Assembly......................................................................207
		Fill with Fork Oil............................................................207
		Installation..................................................................208
	2.20 FRONT FORK: XR 1200X.........................................................209
		Removal.......................................................................209
		Disassembly...................................................................209
		Cleaning and Inspection.......................................................211
		Assembly......................................................................212
		Installation..................................................................214
	2.21 FORK STEM AND BRACKET ASSEMBLY...............................................215
		Removal and Disassembly.......................................................215
		Cleaning, Inspection and Repair...............................................216
		Assembly and Installation.....................................................216
	2.22 BELT GUARD AND DEBRIS DEFLECTOR..............................................217
		Belt Guard: XL Models.........................................................217
		Debris Deflector: XL Models...................................................217
		Belt Guard: XR 1200X..........................................................217
		Debris Deflector: XR 1200X....................................................218
	2.23 REAR FORK....................................................................219
		Removal.......................................................................219
		Disassembly...................................................................219
		Cleaning and Inspection.......................................................220
		Assembly......................................................................220
		Installation..................................................................220
	2.24 SHOCK ABSORBERS..............................................................222
		Removal.......................................................................222
		Cleaning and Inspection.......................................................222
		Installation..................................................................222
		Shock Disposal: Schrader Valve Models.........................................223
	2.25 STABILIZER LINKS.............................................................224
		General.......................................................................224
		Upper Front Stabilizer Link...................................................224
		Lower Front Stabilizer Link...................................................224
		Rear Stabilizer Link..........................................................225
	2.26 FRONT ENGINE MOUNT/ISOLATOR..................................................226
		Removal.......................................................................226
		Installation..................................................................226
	2.27 REAR ENGINE MOUNT/ISOLATOR...................................................228
		Removal.......................................................................228
		Installation..................................................................229
	2.28 THROTTLE CABLES: ALL MODELS..................................................231
		Removal and Disassembly.......................................................231
		Cleaning and Inspection.......................................................232
		Assembly and Installation.....................................................233
	2.29 CLUTCH CONTROL...............................................................235
		Removal and Disassembly.......................................................235
		Assembly and Installation.....................................................238
	2.30 HANDLEBAR....................................................................240
		Removal.......................................................................240
		Installation..................................................................241
		Left Hand Grip................................................................243
	2.31 FRONT FENDER.................................................................244
		All Models....................................................................244
	2.32 FRONT LICENSE PLATE: INDIA MODELS............................................246
		Front License Plate: XL Models (India)........................................246
	2.33 REAR FENDER: ALL XL MODELS EXCEPT XL 883N, XL 1200X/V........................247
		XL 883R/L.....................................................................247
		XL 1200C/C ANV/CP/CA/CB.......................................................249
		Fender Preparation............................................................250
		License Plate Bracket: XL 883R/L..............................................251
		License Plate Bracket: XL 1200C/C ANV/CP/CA/CB................................252
	2.34 REAR FENDER AND LICENSE PLATE BRACKET: XL 883N, XL 1200X/V...................253
		General.......................................................................253
		Removal and Disassembly.......................................................253
		Assembly and Installation.....................................................255
	2.35 REAR FENDER: XR 1200X........................................................258
		Removal.......................................................................258
		Installation..................................................................258
	2.36 SAREE GUARD: INDIA MODELS....................................................259
		Saree Guard: XL 883R, XL 1200C/C ANV (India)..................................259
	2.37 REAR LICENSE PLATE: INDIA MODELS.............................................261
		Rear License Plate: XL Models (India).........................................261
	2.38 JIFFY STAND..................................................................262
		Removal.......................................................................262
		Cleaning and Lubrication......................................................262
		Installation..................................................................263
	2.39 SEAT.........................................................................264
		Seat: XL Models...............................................................264
		Seat: XR 1200X................................................................265
		Passenger Pillion: XR 1200X...................................................266
	2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS...................................267
		Right Footrest and Rear Brake Pedal Assembly..................................267
		Left Footrest and Shift Lever Assembly........................................268
	2.41 RIDER FOOT CONTROLS: XL FORWARD CONTROLS.....................................269
		Right Footrest and Rear Brake Pedal Assembly..................................269
		Left Footrest and Shift Lever Assembly........................................270
		Adjusting Shift Pedal: Forward Controls Models................................271
	2.42 RIDER FOOT CONTROLS: XR 1200X................................................272
		Right Footrest and Rear Brake Pedal Assembly..................................272
		Left Footrest and Shift Lever Assembly........................................273
		Adjusting Shift Lever.........................................................274
	2.43 PASSENGER FOOTRESTS..........................................................275
		XL Models.....................................................................275
		XR 1200X......................................................................276
	2.44 FORK LOCK....................................................................277
		Removal.......................................................................277
		Installation..................................................................278
	2.45 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS...............................279
		Removal.......................................................................279
		Installation..................................................................279
3. ENGINE.............................................................................281
	3.1 FASTENER TORQUE VALUES........................................................283
		Fastener Torque Values in this Chapter........................................283
	3.2 SPECIFICATIONS................................................................287
		Specifications: Sportster Models..............................................287
	3.3 OIL PRESSURE..................................................................292
		Operation.....................................................................292
		Checking Oil Pressure.........................................................293
	3.4 CRANKCASE BREATHING SYSTEM....................................................295
		XL Models.....................................................................295
		XR 1200X......................................................................295
	3.5 TROUBLESHOOTING...............................................................296
		Diagnosing Valve Train Noise..................................................296
		Compression Test..............................................................296
		Cylinder Leakage Test.........................................................296
		Diagnosing Smoking Engine or High Oil Consumption.............................297
		Adjustment and Testing........................................................297
	3.6 ENGINE LUBRICATION SYSTEM.....................................................298
		Oil Pump Operation............................................................298
		Oil Flow: XL Models...........................................................300
		Oil Flow: XR 1200X............................................................300
	3.7 HOW TO USE THIS SECTION.......................................................307
		Typical Symptoms..............................................................307
		Top End Repair................................................................307
		Bottom End Repair.............................................................307
	3.8 TOP END SERVICE...............................................................308
		Engine in Chassis.............................................................308
		Engine Removed from Chassis...................................................309
	3.9 BOTTOM END SERVICE............................................................310
		Engine in Chassis.............................................................310
		Engine Removed From Chassis...................................................311
	3.10 REMOVING ENGINE FROM CHASSIS.................................................312
		Procedure: XL Models..........................................................312
		Procedure: XR 1200X...........................................................315
	3.11 INSTALLING ENGINE IN CHASSIS.................................................320
		Procedure: XL Models..........................................................320
		Procedure: XR 1200X...........................................................323
	3.12 PRECISION COOLING SYSTEM: XR 1200X...........................................326
		General.......................................................................326
		Return Oil Manifold...........................................................326
		Cylinder Head Oil Return Lines................................................327
		Cylinder Head Oil Feed Assembly...............................................328
		Oil Pump Lines................................................................329
		Oil Cooler....................................................................330
	3.13 TOP END OVERHAUL: DISASSEMBLY................................................332
		General.......................................................................332
		Stripping Motorcycle for Top End Repair.......................................332
		Cylinder Heads................................................................333
		Cylinder and Piston...........................................................336
	3.14 CYLINDER HEAD................................................................338
		Disassembly...................................................................338
		Cleaning and Inspection.......................................................338
		Replacing Rocker Arm Bushings.................................................341
		Replacing Valve Guides........................................................342
		Refacing Valve Seats..........................................................346
		Assembly......................................................................348
	3.15 CYLINDER AND PISTON..........................................................350
		Cleaning, Inspection and Repair...............................................350
		Connecting Rod Bushings.......................................................354
	3.16 TOP END OVERHAUL: ASSEMBLY...................................................358
		General.......................................................................358
		Piston and Cylinder...........................................................358
		Tappet Covers, Pushrod Covers and Pushrods....................................359
		Cylinder Head.................................................................361
		Rocker Covers.................................................................363
		Assembling Motorcycle After Top End Repair....................................365
	3.17 BOTTOM END OVERHAUL: DISASSEMBLY.............................................366
		General.......................................................................366
		Oil Pump: XL Models...........................................................366
		Tappets.......................................................................366
		Cam Gear End Play.............................................................366
		Gearcase Cover and Cam Gears: XL Models.......................................367
		Oil Pump Housing/Gearcase Cover and Cam Gears: XR 1200X.......................367
		Crankcase.....................................................................368
	3.18 GEARCASE: XL MODELS..........................................................371
		Bushing Inspection and Removal: XL Only.......................................371
		Bushing Installation: XL Only.................................................371
		Bushing Reaming: XL Only......................................................372
	3.19 CRANKCASE....................................................................375
		General.......................................................................375
		Disassembly...................................................................375
		Fitting Pinion Bearings.......................................................377
		Lapping Engine Main Bearing Races.............................................380
	3.20 OIL PUMP: XL MODELS..........................................................382
		General.......................................................................382
		Removal.......................................................................383
		Disassembly...................................................................383
		Cleaning and Inspection.......................................................383
		Assembly......................................................................383
		Installation..................................................................384
	3.21 OIL PUMP: XR 1200X...........................................................385
		General.......................................................................385
		Disassembly...................................................................386
		Cleaning and Inspection.......................................................387
		Assembly......................................................................388
	3.22 BOTTOM END OVERHAUL: ASSEMBLY................................................390
		Crankcase.....................................................................390
		Cam and Pinion Gear Identification............................................394
		Cam Gears and Gearcase Cover: XL Models.......................................395
		Cam Gears and Gearcase Cover: XR 1200X........................................397
		Tappets.......................................................................400
	3.23 OIL FILTER MOUNT.............................................................402
		General.......................................................................402
		Disassembly...................................................................402
		Cleaning and Inspection.......................................................402
		Assembly......................................................................402
	3.24 OIL TANK.....................................................................403
		Pressure Relief Valve.........................................................403
		Oil Line Routing: XL Models...................................................403
		Oil Line Routing: XR 1200X....................................................403
		Removal.......................................................................403
		Installation..................................................................404
4. FUEL SYSTEM........................................................................407
	4.1 FASTENER TORQUE VALUES........................................................409
		Fastener Torque Values in this Chapter........................................409
	4.2 SPECIFICATIONS: FUEL SYSTEM...................................................412
		Specifications................................................................412
	4.3 AIR CLEANER ASSEMBLY..........................................................413
		XL Models except XL 1200V.....................................................413
		XL 1200V......................................................................413
		XR 1200X......................................................................414
	4.4 FUEL TANK: XL MODELS..........................................................416
		Purging and Disconnecting Fuel Supply Hose....................................416
		Removing Fuel Tank............................................................416
		Cleaning and Inspection.......................................................417
		Installing Fuel Tank..........................................................417
		Connecting Fuel Hose and Filling Fuel Tank....................................418
		Vapor Valve...................................................................418
	4.5 FUEL TANK: XR 1200X...........................................................420
		Purging and Disconnecting Fuel Supply Hose....................................420
		Removing Fuel Tank............................................................420
		Disassemble Fuel Tank.........................................................422
		Cleaning and Inspection.......................................................422
		Assemble Fuel Tank............................................................423
		Installing Fuel Tank..........................................................423
		Connecting Fuel Hose and Filling Fuel Tank....................................424
	4.6 THROTTLE POSITION SENSOR (TPS)................................................425
		General.......................................................................425
		Removal: XL Models............................................................425
		Installation: XL Models.......................................................426
		Removal: XR 1200X.............................................................426
		Installation: XR 1200X........................................................427
	4.7 ENGINE TEMPERATURE (ET) SENSOR................................................428
		General.......................................................................428
		Removal.......................................................................428
		Installation..................................................................429
	4.8 INDUCTION MODULE: XL MODELS...................................................431
		Removal.......................................................................431
		Disassembly...................................................................433
		Assembly......................................................................434
		Installation..................................................................435
	4.9 INDUCTION MODULE: XR 1200X....................................................437
		Removal.......................................................................437
		Disassembly...................................................................438
		Assembly......................................................................439
		Installation..................................................................439
	4.10 IDLE AIR CONTROL (IAC).......................................................441
		General.......................................................................441
		Removal: XL Models............................................................441
		Installation: XL Models.......................................................442
		Removal: XR 1200X.............................................................443
		Installation: XR 1200X........................................................444
	4.11 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR.........................445
		General.......................................................................445
		Removal: XL Models............................................................445
		Installation: XL Models.......................................................446
		Removal: XR 1200X.............................................................446
		Installation: XR 1200X........................................................447
	4.12 OXYGEN (O2) SENSOR...........................................................448
		General.......................................................................448
		Removal.......................................................................448
		Installation..................................................................449
	4.13 EXHAUST SYSTEM: XL MODELS....................................................450
		General.......................................................................450
		Removal.......................................................................451
		Installation..................................................................452
	4.14 EXHAUST SYSTEM: XR 1200X.....................................................454
		General.......................................................................454
		Removal.......................................................................454
		Installation..................................................................455
	4.15 FUEL INJECTORS...............................................................457
		Removal.......................................................................457
		Installation..................................................................458
	4.16 FUEL PUMP....................................................................460
		General.......................................................................460
		Removal.......................................................................460
		Disassembly...................................................................461
		Assembly......................................................................462
		Installation..................................................................463
	4.17 FUEL FILTER ELEMENT..........................................................465
		General.......................................................................465
		Removal.......................................................................465
		Installation..................................................................465
	4.18 FUEL PRESSURE TEST...........................................................466
		General.......................................................................466
		Testing.......................................................................466
	4.19 INTAKE LEAK TEST.............................................................469
		General.......................................................................469
		Leak Tester...................................................................469
		Procedure.....................................................................469
	4.20 EVAPORATIVE EMISSIONS CONTROL................................................471
		General.......................................................................471
		Charcoal Canister.............................................................472
		Vapor Valve: XL Models........................................................473
		Hose Routing..................................................................474
5. DRIVE/TRANSMISSION.................................................................477
	5.1 FASTENER TORQUE VALUES........................................................479
		Fastener Torque Values in this Chapter........................................479
	5.2 SPECIFICATIONS: DRIVE.........................................................481
		Sportster Specifications......................................................481
	5.3 PRIMARY COVER.................................................................482
		Removal.......................................................................482
		Clutch Release Ramp...........................................................483
		Primary Chain Adjuster........................................................484
		Installation..................................................................484
	5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS...........................................486
		Troubleshooting...............................................................486
		Removal.......................................................................486
		Disassembly...................................................................488
		Inspection and Repair: XL Models..............................................488
		Assembly......................................................................490
		Installation..................................................................491
	5.5 PRIMARY DRIVE AND CLUTCH: XR 1200X............................................493
		Troubleshooting...............................................................493
		Removal.......................................................................493
		Disassembly...................................................................495
		Adjusting Screw...............................................................495
		Clutch Pack Cleaning and Inspection...........................................495
		Clutch Shell/Hub Inspection...................................................496
		Clutch Shell Bearing Replacement..............................................497
		Assembly......................................................................498
		Installation..................................................................500
	5.6 DRIVE BELT....................................................................502
		Drive Belt Handling...........................................................502
		Drive Belt: XL Models.........................................................502
		Idler Pulley: XR 1200X........................................................503
		Drive Belt: XR 1200X..........................................................504
	5.7 TRANSMISSION POWER FLOW.......................................................506
		General.......................................................................506
	5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL.....................................508
		General.......................................................................508
		Engine Removal and Disassembly................................................508
	5.9 TRANSMISSION REMOVAL AND DISASSEMBLY..........................................511
		Transmission Removal From Left Crankcase......................................511
		Mainshaft/Countershaft........................................................512
		Mainshaft Disassembly.........................................................512
		Countershaft Disassembly......................................................513
	5.10 TRANSMISSION ASSEMBLY........................................................515
		Mainshaft Assembly............................................................515
		Countershaft Assembly.........................................................515
	5.11 MAIN DRIVE GEAR AND BEARING..................................................517
		General.......................................................................517
		Removal.......................................................................518
		Disassembly...................................................................519
		Assembly......................................................................520
		Installation..................................................................521
	5.12 TRANSMISSION RIGHT CASE BEARINGS.............................................527
		Removal.......................................................................527
		Installation..................................................................527
	5.13 TRANSMISSION LEFT CASE BEARINGS..............................................528
		Removal.......................................................................528
		Installation..................................................................528
	5.14 TRANSMISSION INSTALLATION....................................................529
		General.......................................................................529
		Installation..................................................................529
		Shifter Forks and Drum Assembly...............................................530
		Assembling Crankcases.........................................................531
		Shifter Shaft Installation....................................................532
	5.15 TRANSMISSION SPROCKET........................................................534
		Removal.......................................................................534
		Installation..................................................................535
6. ELECTRICAL.........................................................................537
	6.1 FASTENER TORQUE VALUES........................................................539
		Fastener Torque Values in this Chapter........................................539
	6.2 SPECIFICATIONS: ELECTRICAL....................................................543
		Specifications................................................................543
	6.3 FUSES AND RELAYS..............................................................544
		General.......................................................................544
		Main Fuse.....................................................................544
		Fuses.........................................................................544
		Relays........................................................................545
	6.4 SPEEDOMETER: XL MODELS........................................................546
		Removal.......................................................................546
		Installation..................................................................546
	6.5 SPEEDOMETER AND TACHOMETER: XR 1200X..........................................548
		Speedometer Removal...........................................................548
		Speedometer Installation......................................................548
		Trip Odometer Reset Switch Replacement........................................549
		Tachometer Removal............................................................549
		Tachometer Installation.......................................................549
	6.6 ELECTRONIC CONTROL MODULE (ECM)...............................................550
		General.......................................................................550
		Removal.......................................................................550
		Installation..................................................................551
	6.7 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)...............................552
		General.......................................................................552
		Removal.......................................................................552
		Installation..................................................................552
	6.8 BATTERY CABLES................................................................553
		Removal.......................................................................553
		Installation..................................................................553
	6.9 BATTERY TRAY..................................................................555
		General.......................................................................555
		Removal.......................................................................555
		Installation..................................................................556
	6.10 STARTER......................................................................557
		Removal.......................................................................557
		Touch-Up Paint................................................................557
		Installation..................................................................557
		Solenoid......................................................................558
		Clutch Shaft Assembly.........................................................559
	6.11 IGNITION SWITCH..............................................................561
		Removal.......................................................................561
		Installation..................................................................561
	6.12 SPARK PLUG CABLES............................................................562
		General.......................................................................562
		Removal.......................................................................562
		Installation..................................................................563
	6.13 IGNITION COIL................................................................565
		General.......................................................................565
		Removal.......................................................................565
		Installation..................................................................566
	6.14 HEADLAMP.....................................................................568
		Bulb Replacement..............................................................568
		Headlamp Mounts...............................................................569
	6.15 INDICATOR LAMP MODULE........................................................571
		General.......................................................................571
		Preliminary Disassembly: All Models...........................................571
		Replacement: XL 1200C/C ANV/CP/CA except with Mini-Ape Handlebar..............571
		Replacement: XL 883R/L/N, XL 1200X/V, XL 1200CP/CB with Mini-Ape Handlebar....572
		Replacement: XR 1200X.........................................................572
		Assembly: All Models..........................................................573
	6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V..............................574
		Bulb Replacement Except XL 1200C/C ANV/CP/CA/CB...............................574
		Base Replacement: XL 883R/L and XR 1200X......................................574
		LED Tail Lamp: XL 1200C/C ANV/CP/CA/CB........................................576
	6.17 LICENSE PLATE LAMP MODULE: XL 883N, XL 1200X/V...............................578
		General.......................................................................578
		Removal: Domestic Only........................................................578
		Installation: Domestic Only...................................................579
		Removal: Non-Domestic.........................................................579
		Installation: HDI.............................................................582
	6.18 FRONT TURN SIGNALS...........................................................583
		Bulb Replacement..............................................................583
		All Except XL 1200X...........................................................583
		XL 1200X......................................................................584
	6.19 REAR TURN SIGNALS............................................................586
		General.......................................................................586
		XL 883R/L.....................................................................586
		XL 883N and XL 1200X/V........................................................588
		XL 1200C/C ANV/CP/CA/CB.......................................................590
		XR 1200X......................................................................591
	6.20 REAR LIGHTING CONVERTER MODULE: XL 883N, XL 1200X/V (DOM)....................593
		General.......................................................................593
		Removal.......................................................................593
		Installation..................................................................594
	6.21 REAR STOP LAMP SWITCH........................................................595
		General.......................................................................595
		Replacement...................................................................595
	6.22 CRANK POSITION SENSOR (CKP)..................................................597
		General.......................................................................597
		Removal.......................................................................597
		Installation..................................................................597
	6.23 VOLTAGE REGULATOR............................................................598
		General.......................................................................598
		Removal: XL Models............................................................598
		Installation: XL Models.......................................................599
		Removal: XR 1200X.............................................................599
		Installation: XR 1200X........................................................600
	6.24 ALTERNATOR...................................................................602
		Removal and Disassembly.......................................................602
		Cleaning and Inspection.......................................................603
		Assembly and Installation.....................................................603
	6.25 VEHICLE SPEED SENSOR (VSS)...................................................605
		General.......................................................................605
		Removal.......................................................................605
		Installation..................................................................605
	6.26 NEUTRAL INDICATOR SWITCH.....................................................606
		General.......................................................................606
		Replacement...................................................................606
	6.27 MAIN WIRING HARNESS..........................................................607
		Wire Harness Connectors.......................................................607
		Removal.......................................................................608
		Installation..................................................................610
	6.28 ELECTRICAL CADDIES...........................................................612
		Wire Harness Caddy: XL Models.................................................612
		Wire Harness Caddy: XR 1200X..................................................615
	6.29 JIFFY STAND SENSOR (JSS): INTERNATIONAL MODELS...............................618
		Removal.......................................................................618
		Installation..................................................................618
		Operation.....................................................................619
	6.30 SECURITY SYSTEM/OPTIONAL SIREN...............................................620
		Fob Battery...................................................................620
		Optional Siren................................................................620
		Siren Battery.................................................................621
	6.31 OIL PRESSURE SWITCH..........................................................623
		General.......................................................................623
		Removal.......................................................................623
		Installation..................................................................623
	6.32 HORN.........................................................................625
		Troubleshooting...............................................................625
		Voltage Test..................................................................625
		Replacement: Front Mount......................................................625
		Replacement: Side Mount.......................................................625
	6.33 HANDLEBAR SWITCH ASSEMBLIES..................................................627
		Repair Procedures.............................................................627
		Connectors....................................................................627
	6.34 RIGHT HANDLEBAR SWITCHES.....................................................629
		Removal.......................................................................629
		Disassembly...................................................................629
		Switch Repair/Replacement.....................................................630
		Assembly......................................................................631
		Installation..................................................................632
	6.35 LEFT HANDLEBAR SWITCHES......................................................635
		Removal.......................................................................635
		Disassembly...................................................................635
		Switch Repair and Replacement.................................................635
		Assembly......................................................................636
		Installation..................................................................637
	6.36 PERSONAL IDENTIFICATION NUMBER (PIN).........................................639
		General.......................................................................639
		Initial PIN Entry.............................................................639
		Changing the PIN..............................................................639
	6.37 H-DSSS ACTUATION.............................................................641
		General.......................................................................641
		Sidecar Configuration.........................................................641
		Actuation.....................................................................641
		Fob Assignment................................................................641
		Power Disruption and Configuring..............................................641
	6.38 TSM/HFSM: PASSWORD LEARN.....................................................642
		General.......................................................................642
		Password Learn................................................................642
A. APPENDIX A CONNECTOR REPAIR........................................................645
	A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTOR........................................647
		Autofuse Unsealed Connector Repair............................................647
	A.2 BOSCH COMPACT 1.1M CONNECTOR..................................................648
		Bosch Compact 1.1M Connector..................................................648
	A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR.......................................649
		Delphi 100W Micro-Pack Sealed Connector Repair................................649
		Crimping Terminals............................................................650
	A.4 DELPHI 150 METRI-PACK SEALED CONNECTOR........................................651
		Delphi 150 Metri-Pack Sealed Connector Repair.................................651
	A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTOR......................................653
		Fuse Block Repair.............................................................653
	A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS.....................................654
		Delphi 480 Metri-Pack Unsealed Connector Repair...............................654
	A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTOR......................................655
		Delphi 630 Metri-Pack Unsealed Connector Repair...............................655
	A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING................................656
		Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair.........................656
	A.9 DELPHI METRI-PACK TERMINAL REPAIR.............................................657
		Metri-Pack Terminal Crimps....................................................657
	A.10 DELPHI MICRO 64 SEALED CONNECTOR.............................................659
		Delphi Micro 64 Sealed Connector Repair.......................................659
	A.11 DELPHI GT 150 SEALED CONNECTOR...............................................662
		Delphi GT 150 Sealed Connector Repair.........................................662
	A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR...............................664
		Delphi GT 280 Sealed 73-Terminal ECM Connector................................664
	A.13 DEUTSCH DT SEALED CONNECTOR..................................................666
		Deutsch DT Sealed Connector Repair............................................666
	A.14 DEUTSCH DT SEALED TERMINAL REPAIR............................................670
		Deutsch DT Sealed Terminal Crimps.............................................670
	A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR......................................671
		Deutsch DTM Sealed Mini Terminal Crimps.......................................671
	A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR.........................672
		Deutsch DTM Sealed Solid Barrel Terminal Crimps...............................672
	A.17 JAE MX19 SEALED CONNECTOR....................................................674
		JAE MX19 Sealed Connectors....................................................674
		Crimping Terminals............................................................674
	A.18 MOLEX CMC SEALED CONNECTOR...................................................675
		Molex CMC Sealed Connectors...................................................675
		Crimping Terminals............................................................676
	A.19 MOLEX MX 150 SEALED CONNECTOR................................................677
		Molex MX 150 Sealed Connector Repair..........................................677
		Crimp Terminal to Lead........................................................678
	A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR........................................681
		Tyco 070 Multilock Unsealed Connector Repair..................................681
	A.21 TYCO GET 64 SEALED CONNECTOR.................................................685
		Tyco GET 64 Sealed Connector..................................................685
		Crimping Terminals............................................................686
	A.22 TYCO MCP SEALED CONNECTOR....................................................687
		Tyco MCP Sealed Connector.....................................................687
		Crimping Terminals............................................................688
	A.23 SEALED SPLICE CONNECTOR......................................................689
		Sealed Splice Connector Repair................................................689
B. APPENDIX B WIRING..................................................................691
	B.1 CONNECTORS....................................................................693
		Connector Locations...........................................................693
	B.2 WIRING DIAGRAMS...............................................................696
		Wiring Diagram Information....................................................696
		2013 Sportster Wiring Diagrams................................................698
C. APPENDIX C COMPENSATING SPROCKET...................................................719
	C.1 COMPENSATING SPROCKET.........................................................721
		General.......................................................................721
		Removal and Disassembly.......................................................721
		Cleaning, Inspection and Repair...............................................721
		Sprocket Bearing..............................................................721
		Assembly and Installation.....................................................722
D. APPENDIX D CONVERSIONS.............................................................725
	D.1 METRIC CONVERSION.............................................................727
		Conversion Table..............................................................727
	D.2 FLUID CONVERSIONS.............................................................728
		United States System..........................................................728
		Metric System.................................................................728
		British Imperial System.......................................................728
	D.3 TORQUE CONVERSIONS............................................................729
		United States System..........................................................729
		Metric System.................................................................729
E. APPENDIX E GLOSSARY................................................................731
	E.1 GLOSSARY......................................................................733
		Acronyms and Abbreviations....................................................733
TOOLS.................................................................................737
TORQUE VALUES.........................................................................747
INDEX.................................................................................769

2013 HARLEY DAVIDSON SPORTSTER MODELS SERVICE MANUAL – PDF DOWNLOAD:

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