Engine fuel supply system of motorcycle Harley Sportster XL1200 (2012-2023)

Fastener torque values
The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes Air box to bracket fasteners: XR 1200X 36-60 in·lbs 4.1-6.7 Nm 4.5 FUEL TANK: XR 1200X , Installing Fuel Tank Air cleaner breather screw...

Specifications of fuel system
Table 4-1. Capacities: XL 883 models ITEM XL 883R XL 883L XL 883N U.S. METRIC U.S. METRIC U.S. METRIC Fuel tank (total) 3.3 gal 12.5 L 4.5 gal 17.0 L 3.3 gal 12.5 L Oil tank with filter 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L Transmission...

Air cleaner assembly — removal and installation
XL models except XL 1200V FASTENER TORQUE VALUE Air cleaner breather screw 84-120 in·lbs 9.5-13.6 Nm Air filter screw 40-60 in·lbs 4.5-6.8 Nm Air cleaner cover screw 36-60 in·lbs 4.1-6.8 Nm Removal 1. See Figure 4-1. Remove two screws (1) and trim...

Fuel tank: XL models
Purging and disconnecting fuel supply hose When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. To prevent...

Fuel tank: XR 1200X models
Purging and disconnecting fuel supply hose Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in...

Throttle position sensor (TPS)
Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. See Figure 4-20 or...

Engine temperature sensor (ET) — removal and installation
See Figure 4-26. The ET sensor is located in the top of the rear cylinder head. See the electrical diagnostic manual. Figure 4-26. ET sensor location Removal PART NUMBER TOOL NAME HD-48116-A TEMPERATURE SENSOR SOCKET Warning! To prevent spray of...

Induction module: XL models — removal, installation, disassembly and assembly
Removal Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Warning! To...

Induction module: XR 1200X models — removal, installation, disassembly and assembly
Removal Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. 1. Purge the...

Idle air control (IAC)
Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. XL Models: See...

Temperature manifold absolute pressure (TMAP) sensor
Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. See Figure 4-56 or...

Oxygen sensor (O2) — removal and installation
See Figure 4-62. The O2 sensors are installed in threaded bosses on the inboard side of the front and rear exhaust pipes. For O2 sensor troubleshooting, see the electrical diagnostic manual. Figure 4-62. O2 sensor locations: XL models: 1. Front O2...

Exhaust system: XL models — removal and installation
PART NUMBER TOOL NAME PFSX916 SNAP-ON WRENCH To facilitate removing exhaust pipe header nuts, use SNAP-ON WRENCH (Part No. PFSX916). Figure 4-65. Exhaust system, all XL models: 1. Muffler, front; 2. Muffler, rear; 3. Exhaust pipe, front; 4. Exhaust...

Exhaust system: XR 1200X models — removal and installation
PART NUMBER TOOL NAME PFSX916 SNAP-ON WRENCH To facilitate removing exhaust pipe header nuts, use SNAP-ON WRENCH (Part No. PFSX916). Figure 4-69. Exhaust system: XR 1200X: 1. Fastener, rear muffler mount; 2. Fastener, mount to frame; 3. Fastener,...

Fuel injectors — 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. Warning! Do not use solvents or...

Fuel pump — removal and installation
Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Warning! Do not...

Fuel filter element — removal and installation
Warning! Do not use solvents or other products that contain chlorine on plastic fuel system components. Chlorine can degrade plastic fuel system components, which can cause a loss of fuel system pressure or engine stalling and could result in death...

Fuel pressure test
PART NUMBER TOOL NAME HD-48650 DIGITAL TECHNICIAN II Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could...

Intake leak test
Warning! Do not allow open flame or sparks near propane. Propane is extremely flammable, which could cause death or serious injury. Warning! Read and follow warnings and directions on propane bottle. Failure to follow warnings and directions can...

Evaporative emissions control
Motorcycles sold in some markets have an evaporative (EVAP) emissions control system. Figure 4-86. Evaporative emissions control system (typical): 1. Induction module; 2. Fuel tank (XL models only); 3. Charcoal canister; 4. External vapor valve (XL...