2013 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD
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. Chapters and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. A number of acronyms and abbreviations are used in this document. See the E.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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