Frame and attachments of motorcycle Harley Sportster XL1200 (2012-2023)
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Fastener torque values
The table below lists torque values for all fasteners presented in this chapter. FASTENERTORQUE VALUENotes Axle, front, nut60-65 ft·lbs81-88 Nm2.5 WHEELS, General Axle, front, nut60-65 ft·lbs81-88 Nm2.5 WHEELS, Front Wheel Axle, front, nut60-65...
The table below lists torque values for all fasteners presented in this chapter. FASTENERTORQUE VALUENotes Axle, front, nut60-65 ft·lbs81-88 Nm2.5 WHEELS, General Axle, front, nut60-65 ft·lbs81-88 Nm2.5 WHEELS, Front Wheel Axle, front, nut60-65...
Specifications of motorcycle
Chassis Table 2-1. Dimensions: XL 883 Models ITEMXL 883RXL 883LXL 883N inmminmminmm Wheel base60.0152459.3150659.81519 Road clearance5.61423.8973.999 Seat height*27.369325.564825.7653 * With 180 lb (81.7 kg) rider on seat. Table 2-2. Dimensions: XL...
Chassis Table 2-1. Dimensions: XL 883 Models ITEMXL 883RXL 883LXL 883N inmminmminmm Wheel base60.0152459.3150659.81519 Road clearance5.61423.8973.999 Seat height*27.369325.564825.7653 * With 180 lb (81.7 kg) rider on seat. Table 2-2. Dimensions: XL...
Vehicle identification number (VIN)
General See Figure 2-2. A unique 17-digit serial or Vehicle Identification Number (VIN) is assigned to each motorcycle. Refer to Table 2-11. Location See Figure 2-1. The full 17-digit VIN is stamped on the right side of the frame near the steering...
General See Figure 2-2. A unique 17-digit serial or Vehicle Identification Number (VIN) is assigned to each motorcycle. Refer to Table 2-11. Location See Figure 2-1. The full 17-digit VIN is stamped on the right side of the frame near the steering...
Left side cover — removal and installation
See Figure 2-133. The left side cover provides access to the battery (1), fuses (3, 4) and diagnostic connector (5). Figure 2-133. main fuse and battery location: all models: 1. Battery; 2. Positive (+) battery terminal (under protective rubber...
See Figure 2-133. The left side cover provides access to the battery (1), fuses (3, 4) and diagnostic connector (5). Figure 2-133. main fuse and battery location: all models: 1. Battery; 2. Positive (+) battery terminal (under protective rubber...
Engine stabilizer links — removal and installation
The stabilizer link system allows the engine to move on its rubber engine mounts while maintaining engine-to-frame alignment. The stabilizer links provide a fixed alignment, and no adjustment is necessary or possible. The spherical ball end of the...
The stabilizer link system allows the engine to move on its rubber engine mounts while maintaining engine-to-frame alignment. The stabilizer links provide a fixed alignment, and no adjustment is necessary or possible. The spherical ball end of the...
Front engine mount/isolator — removal and installation
Removal PART NUMBERTOOL NAMEHD-45968FAT JACK 1. Position motorcycle on a suitable lift. 2. Remove the exhaust system. See 4.13 EXHAUST SYSTEM: XL MODELS or 4.14 EXHAUST SYSTEM: XR 1200X. 3. XR 1200X: Remove the air box assembly. See 4.3 AIR CLEANER...
Removal PART NUMBERTOOL NAMEHD-45968FAT JACK 1. Position motorcycle on a suitable lift. 2. Remove the exhaust system. See 4.13 EXHAUST SYSTEM: XL MODELS or 4.14 EXHAUST SYSTEM: XR 1200X. 3. XR 1200X: Remove the air box assembly. See 4.3 AIR CLEANER...
Rear engine mount/isolator — removal and installation
Removal PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK 1. XR 1200X: Remove the air box assembly. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X. 2. Remove exhaust system. See 4.13 EXHAUST SYSTEM: XL MODELS or 4.14 EXHAUST SYSTEM: XR 1200X. 3. With...
Removal PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK 1. XR 1200X: Remove the air box assembly. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X. 2. Remove exhaust system. See 4.13 EXHAUST SYSTEM: XL MODELS or 4.14 EXHAUST SYSTEM: XR 1200X. 3. With...
Throttle cables: all models
Removal and disassembly Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Purge the fuel...
Removal and disassembly Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Purge the fuel...
Clutch control — removal and installation
Removal and disassembly Clutch cable: lower Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 1. Remove main fuse. 2. Mid-mount Controls: Remove left side rider footrest...
Removal and disassembly Clutch cable: lower Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 1. Remove main fuse. 2. Mid-mount Controls: Remove left side rider footrest...
Front fender — removal and installation
All models FASTENERTORQUE VALUE Fender to forks, front: XL except XL 1200X96-156 in·lbs10.9-17.6 Nm Fenderto fork brace, front: XL 1200X30-42 in·lbs3.4-4.7 Nm Fork brace to forks: XL 1200X18-22 ft·lbs25-30 Nm Fenderto bracket, front: XR 1200X30-60...
All models FASTENERTORQUE VALUE Fender to forks, front: XL except XL 1200X96-156 in·lbs10.9-17.6 Nm Fenderto fork brace, front: XL 1200X30-42 in·lbs3.4-4.7 Nm Fork brace to forks: XL 1200X18-22 ft·lbs25-30 Nm Fenderto bracket, front: XR 1200X30-60...
Front license plate: India models
Front license plate: XL models (India) FASTENERTORQUE VALUE License plate fasteners, front: XL 883L/N/R (India)10-15 in·lbs1.1-1.7 Nm License plate fasteners, front: XL 1200X/C/C ANV (India)10-15 in·lbs1.1-1.7 Nm XL 883L/N/R 1. See Figure 2-195....
Front license plate: XL models (India) FASTENERTORQUE VALUE License plate fasteners, front: XL 883L/N/R (India)10-15 in·lbs1.1-1.7 Nm License plate fasteners, front: XL 1200X/C/C ANV (India)10-15 in·lbs1.1-1.7 Nm XL 883L/N/R 1. See Figure 2-195....
Rear fender: all XL models except XL 883N, XL 1200X/V
XL 883R/L FASTENERTORQUE VALUE Seat post bolt96-156 in·lbs10.9-17.6 Nm Turn signal stalk locknut132-216 in·lbs14.9-24.4 Nm Fender, rear, mounting fastener132-216 in·lbs14.9-24.4 Nm Removal 1. Remove seat. Warning! To prevent accidental vehicle...
XL 883R/L FASTENERTORQUE VALUE Seat post bolt96-156 in·lbs10.9-17.6 Nm Turn signal stalk locknut132-216 in·lbs14.9-24.4 Nm Fender, rear, mounting fastener132-216 in·lbs14.9-24.4 Nm Removal 1. Remove seat. Warning! To prevent accidental vehicle...
Rear fender and license plate bracket: XL 883N, XL 1200X/V
Certain XL 883N and XL 1200X/V models have a side-mount license plate bracket. This bracket includes a license plate lamp module. Note. Due to local regulations, this side mount license plate bracket may not be offered in all markets. Certain models...
Certain XL 883N and XL 1200X/V models have a side-mount license plate bracket. This bracket includes a license plate lamp module. Note. Due to local regulations, this side mount license plate bracket may not be offered in all markets. Certain models...
Rear fender: XR 1200X — removal and installation
Removal 1. Remove rider's seat and passenger pillion. Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 2. Remove main fuse. 3. See Figure 2-214. Remove three bolts and...
Removal 1. Remove rider's seat and passenger pillion. Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 2. Remove main fuse. 3. See Figure 2-214. Remove three bolts and...
Saree guard: India models
Saree guard: XL 883R, XL 1200C/C ANV (India) FASTENERTORQUE VALUE Strut cover fastener96-156 in·lbs10.9-17.6 Nm Turn signal stalk locknut96-156 in·lbs10.9-17.6 Nm Strut cover fastener96-156 in·lbs10.9-17.6 Nm Saree guard, left-front, passenger...
Saree guard: XL 883R, XL 1200C/C ANV (India) FASTENERTORQUE VALUE Strut cover fastener96-156 in·lbs10.9-17.6 Nm Turn signal stalk locknut96-156 in·lbs10.9-17.6 Nm Strut cover fastener96-156 in·lbs10.9-17.6 Nm Saree guard, left-front, passenger...
Rear license plate: India models
Rear license plate: XL models (India) FASTENERTORQUE VALUE License plate screw: XL 883L/R (India)10-15 in·lbs1.1-1.7 Nm License plate screw: XL 883N, XL 1200X (India)10-15 in·lbs1.1-1.7 Nm XL 883L/R, XL 1200C/C ANV 1. See Figure 2-217. Assemble the...
Rear license plate: XL models (India) FASTENERTORQUE VALUE License plate screw: XL 883L/R (India)10-15 in·lbs1.1-1.7 Nm License plate screw: XL 883N, XL 1200X (India)10-15 in·lbs1.1-1.7 Nm XL 883L/R, XL 1200C/C ANV 1. See Figure 2-217. Assemble the...
Jiffy stand — removal and installation
Removal Warning! The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result...
Removal Warning! The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result...
Seat — removal and installation
Seat: XL models FASTENERTORQUE VALUESeat mounting screw: XL Models20-40 in·lbs2.3-4.5 Nm Removal 1. Remove screw to detach seat from rear fender. 2. Slide seat forward. 3. See Figure 2-223. Lift up slightly to detach keyhole bracket from seat post....
Seat: XL models FASTENERTORQUE VALUESeat mounting screw: XL Models20-40 in·lbs2.3-4.5 Nm Removal 1. Remove screw to detach seat from rear fender. 2. Slide seat forward. 3. See Figure 2-223. Lift up slightly to detach keyhole bracket from seat post....
Rider foot controls: XL mid-mount controls
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest mount fastener45-50 ft·lbs61-68 Nm Brake pedal clevis screw13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Brake rod to bell crank screw120-180...
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest mount fastener45-50 ft·lbs61-68 Nm Brake pedal clevis screw13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Brake rod to bell crank screw120-180...
Rider foot controls: XL forward controls
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest mount fastener45-50 ft·lbs61-68 Nm Brake pedal clevis screw13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Brake rod to bell crank screw120-180...
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest mount fastener45-50 ft·lbs61-68 Nm Brake pedal clevis screw13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Brake rod to bell crank screw120-180...
Rider foot controls: XR 1200X
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest clevis fastener: XR 1200X13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Removal 1. Remove clevis pin connecting master cylinder to brake pedal. See 2.12...
Right footrest and rear brake pedal assembly FASTENERTORQUE VALUE Footrest clevis fastener: XR 1200X13-17 ft·lbs17.6-23.0 Nm Footrest wear peg72-108 in·lbs8.1-12.2 Nm Removal 1. Remove clevis pin connecting master cylinder to brake pedal. See 2.12...
Passenger footrests — removal and installation
XL models FASTENERTORQUE VALUEPassenger footrest support bracket fastener: XL Models45-50 ft·lbs61-68 Nm Removal 1. See Figure 2-238. Remove retaining ring (1), clevis pin (2), footrest (3) and spring washer (4). Discard retaining ring. Figure...
XL models FASTENERTORQUE VALUEPassenger footrest support bracket fastener: XL Models45-50 ft·lbs61-68 Nm Removal 1. See Figure 2-238. Remove retaining ring (1), clevis pin (2), footrest (3) and spring washer (4). Discard retaining ring. Figure...
Fork lock — removal and installation
Removal Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Purge the fuel supply hose of...
Removal Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Purge the fuel supply hose of...
Medallions, serialized badges and tank emblems
Removal 1. Mark location of emblem with masking tape. Note. Wear protective gloves. 2. Saw behind emblem with mono-filament fishing line or waxed dental floss to remove emblem. 3. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to remove remaining foam...
Removal 1. Mark location of emblem with masking tape. Note. Wear protective gloves. 2. Saw behind emblem with mono-filament fishing line or waxed dental floss to remove emblem. 3. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to remove remaining foam...
- Information for owner
- Maintenance
- Troubleshooting
- Engine and systems
- Engine repair
- Lubrication system
- Fuel system
- Transmission
- Running gear and frame
- Frame and hinged elements
- Front suspension and handlebar
- Rear suspension
- Brake system
- Wheels and tires
- Electric equipment
- Equipment and devices
- Lighting and lamps
- Starting and charging system
- Electrical circuits