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. FASTENER TORQUE VALUE Notes Axle, front, nut 60-65 ft·lbs 81-88 Nm 2.5 WHEELS, General Axle, front, nut 60-65 ft·lbs 81-88 Nm 2.5 WHEELS, Front Wheel Axle, front, nut...
The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes Axle, front, nut 60-65 ft·lbs 81-88 Nm 2.5 WHEELS, General Axle, front, nut 60-65 ft·lbs 81-88 Nm 2.5 WHEELS, Front Wheel Axle, front, nut...
Specifications of motorcycle
Chassis Table 2-1. Dimensions: XL 883 Models ITEM XL 883R XL 883L XL 883N in mm in mm in mm Wheel base 60.0 1524 59.3 1506 59.8 1519 Road clearance 5.6 142 3.8 97 3.9 99 Seat height* 27.3 693 25.5 648 25.7 653 * With 180 lb (81.7 kg) rider on seat....
Chassis Table 2-1. Dimensions: XL 883 Models ITEM XL 883R XL 883L XL 883N in mm in mm in mm Wheel base 60.0 1524 59.3 1506 59.8 1519 Road clearance 5.6 142 3.8 97 3.9 99 Seat height* 27.3 693 25.5 648 25.7 653 * With 180 lb (81.7 kg) rider on seat....
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 NUMBER TOOL NAME HD-45968 FAT 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...
Removal PART NUMBER TOOL NAME HD-45968 FAT 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...
Rear engine mount/isolator — removal and installation
Removal PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT 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....
Removal PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT 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....
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 FASTENER TORQUE VALUE Fender to forks, front: XL except XL 1200X 96-156 in·lbs 10.9-17.6 Nm Fenderto fork brace, front: XL 1200X 30-42 in·lbs 3.4-4.7 Nm Fork brace to forks: XL 1200X 18-22 ft·lbs 25-30 Nm Fenderto bracket, front: XR 1200X...
All models FASTENER TORQUE VALUE Fender to forks, front: XL except XL 1200X 96-156 in·lbs 10.9-17.6 Nm Fenderto fork brace, front: XL 1200X 30-42 in·lbs 3.4-4.7 Nm Fork brace to forks: XL 1200X 18-22 ft·lbs 25-30 Nm Fenderto bracket, front: XR 1200X...
Front license plate: India models
Front license plate: XL models (India) FASTENER TORQUE VALUE License plate fasteners, front: XL 883L/N/R (India) 10-15 in·lbs 1.1-1.7 Nm License plate fasteners, front: XL 1200X/C/C ANV (India) 10-15 in·lbs 1.1-1.7 Nm XL 883L/N/R 1. See Figure...
Front license plate: XL models (India) FASTENER TORQUE VALUE License plate fasteners, front: XL 883L/N/R (India) 10-15 in·lbs 1.1-1.7 Nm License plate fasteners, front: XL 1200X/C/C ANV (India) 10-15 in·lbs 1.1-1.7 Nm XL 883L/N/R 1. See Figure...
Rear fender: all XL models except XL 883N, XL 1200X/V
XL 883R/L FASTENER TORQUE VALUE Seat post bolt 96-156 in·lbs 10.9-17.6 Nm Turn signal stalk locknut 132-216 in·lbs 14.9-24.4 Nm Fender, rear, mounting fastener 132-216 in·lbs 14.9-24.4 Nm Removal 1. Remove seat. Warning! To prevent accidental...
XL 883R/L FASTENER TORQUE VALUE Seat post bolt 96-156 in·lbs 10.9-17.6 Nm Turn signal stalk locknut 132-216 in·lbs 14.9-24.4 Nm Fender, rear, mounting fastener 132-216 in·lbs 14.9-24.4 Nm Removal 1. Remove seat. Warning! To prevent accidental...
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) FASTENER TORQUE VALUE Strut cover fastener 96-156 in·lbs 10.9-17.6 Nm Turn signal stalk locknut 96-156 in·lbs 10.9-17.6 Nm Strut cover fastener 96-156 in·lbs 10.9-17.6 Nm Saree guard, left-front,...
Saree guard: XL 883R, XL 1200C/C ANV (India) FASTENER TORQUE VALUE Strut cover fastener 96-156 in·lbs 10.9-17.6 Nm Turn signal stalk locknut 96-156 in·lbs 10.9-17.6 Nm Strut cover fastener 96-156 in·lbs 10.9-17.6 Nm Saree guard, left-front,...
Rear license plate: India models
Rear license plate: XL models (India) FASTENER TORQUE VALUE License plate screw: XL 883L/R (India) 10-15 in·lbs 1.1-1.7 Nm License plate screw: XL 883N, XL 1200X (India) 10-15 in·lbs 1.1-1.7 Nm XL 883L/R, XL 1200C/C ANV 1. See Figure 2-217. Assemble...
Rear license plate: XL models (India) FASTENER TORQUE VALUE License plate screw: XL 883L/R (India) 10-15 in·lbs 1.1-1.7 Nm License plate screw: XL 883N, XL 1200X (India) 10-15 in·lbs 1.1-1.7 Nm XL 883L/R, XL 1200C/C ANV 1. See Figure 2-217. Assemble...
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 FASTENER TORQUE VALUE Seat mounting screw: XL Models 20-40 in·lbs 2.3-4.5 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...
Seat: XL models FASTENER TORQUE VALUE Seat mounting screw: XL Models 20-40 in·lbs 2.3-4.5 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...
Rider foot controls: XL mid-mount controls
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest mount fastener 45-50 ft·lbs 61-68 Nm Brake pedal clevis screw 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Brake rod to bell crank screw 120-180...
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest mount fastener 45-50 ft·lbs 61-68 Nm Brake pedal clevis screw 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Brake rod to bell crank screw 120-180...
Rider foot controls: XL forward controls
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest mount fastener 45-50 ft·lbs 61-68 Nm Brake pedal clevis screw 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Brake rod to bell crank screw 120-180...
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest mount fastener 45-50 ft·lbs 61-68 Nm Brake pedal clevis screw 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Brake rod to bell crank screw 120-180...
Rider foot controls: XR 1200X
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest clevis fastener: XR 1200X 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Removal 1. Remove clevis pin connecting master cylinder to brake pedal. See...
Right footrest and rear brake pedal assembly FASTENER TORQUE VALUE Footrest clevis fastener: XR 1200X 13-17 ft·lbs 17.6-23.0 Nm Footrest wear peg 72-108 in·lbs 8.1-12.2 Nm Removal 1. Remove clevis pin connecting master cylinder to brake pedal. See...
Passenger footrests — removal and installation
XL models FASTENER TORQUE VALUE Passenger footrest support bracket fastener: XL Models 45-50 ft·lbs 61-68 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 FASTENER TORQUE VALUE Passenger footrest support bracket fastener: XL Models 45-50 ft·lbs 61-68 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