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 vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. See Figure 2-197. Disconnect the rear lighting connector [7] (2) housings.
![](https://motoinstruction.ru/img/harley/12/117814.jpg)
Figure 2-197. Rear lighting connector [7]
4. Access fender hardware.
- a. Remove lower shock bolts.
- b. Raise motorcycle to lower rear wheel.
5. Remove the tail lamp assembly.
- a. Remove the tail lamp lens and bulb. See 6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V, Base Replacement: XL 883R/L and XR 1200X.
- b. See Figure 2-198. Unplug left [19] (1) and right [18] (2) turn signal connectors from rear lighting circuit board.
- c. Pull turn signal wiring harnesses thru holes in tail lamp base and rear fender.
- d. Disengage turn signal wiring harnesses from wire retention brackets.
![](https://motoinstruction.ru/img/harley/12/117815.jpg)
Figure 2-198. Tail lamp housing: 1. Left turn signal connector [19]; 2. Right turn signal connector [18]; 3. Rear lighting power connector [94]; 4. Tail lamp connector [93]; 5. Screw with washer
6. See Figure 2-199. Remove rear turn signal stalk locknuts (1) from inside rear fender on both sides.
![](https://motoinstruction.ru/img/harley/12/117816.jpg)
Figure 2-199. Rear fender, strut cover and turn signal lamp assembly: 1. Rear turn signal stalk nut (2); 2. Forward fender support screw with washer (2); 3. Aft fender support screw with washer (2); 4. Forward fender support nut (2); 5. Aft fender support nut plate (2); 6. Wire retention bracket; 7. Rear lighting wiring harness and conduit
- a. See Figure 2-200. Support fender and remove front strut cover fastener (4) with washer (3) and locknut (1), and rear strut cover fastener (4) with washer (3) and clip nut (5) on both sides.
- b. Remove rear fender strut covers with attached turn signal assemblies.
- c. Remove bolt (11), seat post (7) and washer (8) to detach top of fender from frame cross member tab.
- d. Carefully remove rear fender with attached license plate bracket, tail lamp base and wire harness.
![](https://motoinstruction.ru/img/harley/12/117817.jpg)
Figure 2-200. Rear fender assembly: XL 883R/L: 1. Locknut; 2. Rear strut cover fastener; 3. Washer; 4. Front strut cover fastener; 5. Clip nut; 6. Inner fender brace; 7. Seat post; 8. Washer; 9. Tee spacer; 10. Grommet; 11. Bolt
Installation
1. Carefully install rear fender onto motorcycle.
2. See Figure 2-200. Align holes in fender with those in struts. Support fender and install fasteners (4, 2) through fender struts and fender to hold fender in place.
3. Route rear lighting harness connector [7B] between frame cross member and top of oil tank.
4. Connect housings [7].
5. Secure front of fender with bolt (11), washer (8) and seat post (7). Finger-tighten.
6. H-DSSS equipped models: Make sure antenna harness is not pinched between fender and frame crossmember.
7. Remove fasteners (4, 2) and install fender strut cover with attached turn signal assembly to fender strut. Push turn signal wiring harness through openings in strut and fender.
8. Install locknut (1) onto turn signal stalk from inside fender. Finger-tighten.
9. Secure fender to strut with fasteners (4), washer (3) and locknut (1) in forward mounting hole. Install fastener (2), washer (3) and clip nut (5) in aft mounting hole. Finger-tighten.
10. In sequence, tighten all fender mounting hardware:
- a. Tighten bolt and seat post to 96-156 in·lbs (10.9-17.6 Nm).
- b. Tighten turn signal stalk locknuts to 132-216 in·lbs (14.9-24.4 Nm).
- c. Tighten fender mounting fasteners to 132-216 in·lbs (14.9-24.4 Nm).
11. Install the tail lamp assembly.
- a. Route turn signal wiring harnesses through the wire retention brackets.
- b. Pull turn signal wiring harnesses through holes in rear fender and tail lamp base.
- c. See Figure 2-198. Connect tail lamp connector [94] (3) and left [19] (1) and right [18] (2) turn signal connectors.
- d. Install the tail lamp lens and bulb. See 6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V, Base Replacement: XL 883R/L and XR 1200X.
12. Install main fuse.
Warning! Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
13. Install seat.
14. Verify license plate lamp, tail lamp, stop lamp and turn signals.
XL 1200C/C ANV/CP/CA/CB
FASTENER | TORQUE VALUE | |
Seat post bolt | 96-156 in·lbs | 10.9-17.6 Nm |
Turn signal stalk locknut | 96-156 in·lbs | 10.9-17.6 Nm |
Fender, rear, mounting fastener | 96-156 in·lbs | 10.9-17.6 Nm |
Removal
1. Remove seat.
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 2-201. Disconnect the right [18] (3) and left [19] (4) turn signal connectors and the tail lamp connector [40] (2).
![](https://motoinstruction.ru/img/harley/12/117818.jpg)
Figure 2-201. Turn signal wire harness: XL 1200C/C ANV/CP/CA/CB: 1. Main harness connector [7]; 2. Tail lamp connector [40]; 3. RH turn signal connector [18]; 4. LH turn signal connector [19]
4. Remove the lower shock bolts and lower the rear wheel to access the fender hardware.
5. See Figure 2-202. Route the turn signal wire harness through the openings (4) in the fender and from the retention bracket (3).
![](https://motoinstruction.ru/img/harley/12/117819.jpg)
Figure 2-202. Inner rear fender: XL 1200C/C ANV/CP: 1. Fender brace; 2. Retention clip; 3. Retention bracket; 4. Fender opening
6. See Figure 2-203. Remove rear turn signal stalk nuts (1) from inside rear fender on both sides.
![](https://motoinstruction.ru/img/harley/12/117820.jpg)
Figure 2-203. Rear fender assembly: XL 1200C/C ANV/CP: 1. Locknut; 2. Rear strut cover fastener; 3. Washer; 4. Front strut cover fastener; 5. Clip nut; 6. Inner fender brace; 7. Seat post; 8. Washer; 9. Tee spacer; 10. Grommet; 11. Bolt; 12. Subharness; 13. Wire retention bracket (2)
7. Support the fender and remove the front (4) and rear (2) fender fasteners with washers (3) and strut covers with attached turn signal assemblies from rear fender struts.
8. Remove bolt (11), seat post (7) and flat washer (8) to detach top of rear fender from frame cross member tab.
9. Carefully remove rear fender from motorcycle.
Installation
1. Install rear fender onto motorcycle. Align holes in fender with those in struts. Temporarily install screws to hold fender in place.
2. Route tail lamp harness connector between frame cross member and top of oil tank. Connect tail lamp housings [40].
3. See Figure 2-203. Secure front of fender with bolt (11), washer (8) and seat post (7). Finger-tighten.
4. H-DSSS equipped models: Make sure antenna harness is not pinched between fender and frame crossmember.
5. Remove bolts from right side of fender. Install fender strut cover with attached turn signal assembly to fender strut with the locknut (1).
6. Secure fender to strut with fasteners (4), washer (3) and locknut (1) in forward mounting hole. Install fastener (2), washer (3) and clip nut (5) in aft mounting hole. Finger-tighten screws only at this time.
7. Push turn signal wiring harness through openings in strut and fender. Install nut onto turn signal stalk from inside fender. Finger-tighten.
8. Now tighten all fender mounting hardware in the following sequence:
- a. Tighten bolt (11) and seat post (7) to 96-156 in·lbs (10.9-17.6 Nm).
- b. Tighten turn signal stalk nuts (1) to 96-156 in·lbs (10.9-17.6 Nm).
- c. Tighten fasteners (2, 4) to 96-156 in·lbs (10.9-17.6 Nm).
9. Install the lower lower shock bolts and lower the rear wheel.
10. See Figure 2-201. Connect the right [18] (3) and left [19] (4) turn signal connectors and the tail lamp connector [40] (2).
11. Install main fuse.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
12. Install seat.
Warning! Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury.
13. Verify turn signals, tail lamp, and stop lamp.
Fender preparation
Tail lamp assembly
XL 883R/L: Replace the tail lamp. See 6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V, Base Replacement: XL 883R/L and XR 1200X.
XL 883N and XL 1200X/V: The tail lamps are the rear turn signals.
XL 1200C/C ANV/CP/CA/CB: Replace LED tail lamp assembly. See 6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V, LED Tail Lamp: XL 1200C/C ANV/CP/CA/CB.
License plate lamp module: XL 883N and XL 1200X/V
Replace the license plate lamp module. See 6.17 LICENSE PLATE LAMP MODULE: XL 883N, XL 1200X/V.
Seat nut
Remove the C-clip and the seat nut. Replace with a new seat nut kit.
Fender extension
1. See Figure 2-204. Drill out rivets (1) securing rear fender extension (2) to fender with a 1/4 drill bit.
![](https://motoinstruction.ru/img/harley/12/117821.jpg)
Figure 2-204. Fender extension: 1. Rivet; 2. Extension; 3. Washer; 4. Rivet; 5. Wire retention bracket
2. Rivet fender extension to fender backed by a washer (3).
Wire harness with conduit
1. Protect fender. Clean inside of fender with a mixture of alcohol and water. Allow to air-dry.
2. Position new wire harness and conduit inside fender in same location. Insert end of wiring harness with D plug through D hole in front of fender. Insert plug.
3. Slide conduit toward D plug as far as it will go. Insert other end of wiring harness through housing hole in rear of fender.
4. Remove adhesive tape backing from conduit and press conduit in place along right side curve of fender.
Wire retention bracket
1. See Figure 2-204. Drill out rivets (4) securing wire retention brackets (5) with a 1/4 in drill.
2. Rivet wire retention brackets to fender.
License plate bracket: XL 883R/L
FASTENER | TORQUE VALUE | |
License plate support bracket screws | 20-25 in·lbs | 2.3-2.8 Nm |
License plate bolt | 20-25 in·lbs | 2.3-2.8 Nm |
Removal
1. See Figure 2-205. Loosen the keps nut and remove the license plate.
![](https://motoinstruction.ru/img/harley/12/117822.jpg)
Figure 2-205. License plate bracket: XL models except XL 883N, XL 1200X/C/CP: 1. Reflector; 2. Bracket; 3. Clamp; 4. Support; 5. Washer; 6. Keps nut; 7. Fastener; 8. Screw; 9. Nut
2. Remove the keps nut, washer and bolt to remove the clamp and the bracket.
3. Remove the three screws to remove the support bracket from the fender.
Installation
1. Mount the support bracket on the fender with the screws.
2. Fit the fender brace to the middle screw.
3. Secure with washers and nuts. Tighten the screws to 20-25 in·lbs (2.3-2.8 Nm).
4. Assemble the bracket and the clamp to the support bracket with the bolt, washer and keps nut.
5. Install the license plate. Tighten the keps nut to 20-25 in·lbs (2.3-2.8 Nm).
License plate bracket: XL 1200C/C ANV/CP/CA/CB
FASTENER | TORQUE VALUE | |
License plate bracket, rear, fasteners: XL 1200C/C ANV/CP/CA/CB | 20-25 in·lbs | 2.3-2.8 Nm |
License plate, rear, keps nut, XL 1200C/C ANV/CP/CA/CB | 20-25 in·lbs | 2.3-2.8 Nm |
1. See Figure 2-206. Disassemble the upper license plate bracket bolt (4), washer (5) and keps nut (6).
![](https://motoinstruction.ru/img/harley/12/117823.jpg)
Figure 2-206. License plate bracket: 1. Lower bracket; 2. Fastener; 3. Upper bracket; 4. Bolt; 5. Washer; 6. Keps nut
2. Remove the two fasteners (2) from the tail lamp base to remove the lower license plate bracket (1).
3. Install the lower bracket and fasteners. Tighten to 20-25 in·lbs (2.3-2.8 Nm).
4. Install the tail lamp. See 6.16 TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200X/V, LED Tail Lamp: XL 1200C/C ANV/CP/CA/CB.
5. Assemble the upper bracket (3) with bolt (4), washer (5) and keps nut (6).
6. Install the license plate and tighten the keps nut to 20-25 in·lbs (2.3-2.8 Nm).