Motorcycle engine repair Harley Sportster XL1200 (2012-2023)

Fastener torque values
The table below lists torque values for all fasteners presented in this chapter. FASTENERTORQUE VALUENotes Axle, rear, nut95-105 ft·lbs129-142 Nm3.11 INSTALLING ENGINE IN CHASSIS, Procedure: XL Models Axle, rear, nut95-105 ft·lbs129-142 Nm3.11...

Specifications of engine
Table 3-1. Engine ITEMXL 883 MODELSXL 1200 MODELSXR1200X Number of cylinders2 Type4-cycle, 45 degree, V-twin, air cooled Compression ratio8.9-19.7-110.0-1 Bore3.000 in76.20 mm3.500 in88.90 mm3.500 in88.90 mm Stroke3.812 in96.82 mm3.812 in96.82...

Diagnosing valve train noise
To diagnose and correct noisy hydraulic lifters and valve train components, use the following procedures: 1. With engine and oil at normal operating temperature, check oil pressure at 2000 rpm. If oil pressure is above 50 psi (345 kPa) or below 5...

Cylinder compression test
PART NUMBERTOOL NAMEHD-33223-1CYLINDER COMPRESSION GAUGE Combustion chamber leakage may cause performance issues. A compression test can help determine the source of cylinder leakage. Test engine at normal operating temperature 1. Disconnect spark...

Cylinder leakage test
PART NUMBERTOOL NAMEHD-35667-ACYLINDER LEAKDOWN TESTER The cylinder leakage test pinpoints engine problems including leaking valves, worn, damaged or stuck piston rings and blown head gaskets. Use CYLINDER LEAKDOWN TESTER (Part # HD-35667-A). Follow...

Diagnosing smoking engine or high oil consumption
Before removing the cylinder heads, check for compression and cylinder leakage. See 3.5 TROUBLESHOOTING, Compression Test or 3.5 TROUBLESHOOTING, Cylinder Leakage Test. Check prior to cylinder head removal 1. Oil tank overfilled. 2. Oil carryover....

How to use engine repair section
Typical symptoms Always use all available symptoms to begin a diagnosis. Symptoms indicating a need for engine repair are often misleading. If more than one symptom is present, possible causes can be narrowed down to make a partial diagnosis. An...

Engine top end service
Table 3-24. Engine in chassis SERVICE PROCEDURECOMPONENT REPAIR PROCEDURES Remove parts necessary to gain access to all components above cylinder deck. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End Repair. Continue with...

Engine bottom end service
Table 3-26. Engine in chassis: cam compartment service SERVICE PROCEDURECOMPONENT REPAIR PROCEDURES Remove parts necessary to gain access to all components above cylinder deck. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End...

Removing engine from chassis: XL models
PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK HD-46284ENGINE HOOK 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...

Removing engine from chassis: XR 1200X models
PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK HD-46284ENGINE HOOK 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...

Installing engine in chassis XL models
PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK HD-46284ENGINE HOOK FASTENERTORQUE VALUE Isolator mount, front, screw25-35 ft·lbs33.9-47.5 Nm Isolator mount, rear, screw25-35 ft·lbs33.9-47.5 Nm Fork, rear, pivot/engine mount bolt60-70...

Installing engine in chassis XR 1200X models
PART NUMBERTOOL NAME HD-45967SHOP DOLLY HD-45968FAT JACK HD-46284ENGINE HOOK FASTENERTORQUE VALUE Isolator mount, front, screw25-35 ft·lbs33.9-47.5 Nm Isolator mount, rear, screw25-35 ft·lbs33.9-47.5 Nm Fork, rear, pivot/engine mount bolt60-70...

Engine top end overhaul: disassembly
This section describes disassembling the top end of the engine, from the cylinder deck up. To perform a complete top end overhaul, follow all steps listed in this section. Then follow all steps listed in the following sections, including inspection...

Cylinder head — disassembly
PART NUMBERTOOL NAMEHD-34736-BVALVE SPRING COMPRESSOR 1. See Figure 3-49. Clamp VALVE SPRING COMPRESSOR (Part # HD-34736-B) in vise and compress valve spring. Figure 3-49. Valve spring compressor 2. See Figure 3-50. Remove valve collar retainers...

Cylinder head — cleaning and inspection
PART NUMBERTOOL NAME B-45525VALVE GUIDE HONE HD-34751VALVE GUIDE CLEANING BRUSH HD-96796-47VALVE SPRING TESTER Cylinder heads Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear...

Cylinder head — replacing rocker arm bushings
PART NUMBERTOOL NAMEHD-94804-57ROCKER ARM BUSHING REAMER 1. See Figure 3-58. To replace worn bushings, press or drive them from the rocker arm. If bushing is difficult to remove, turn a 9/16-18 tap into bushing. From opposite side of rocker arm,...

Cylinder head — replacing valve guides
PART NUMBERTOOL NAME B-45523VALVE GUIDE REAMER B-45524VALVE GUIDE REMOVER/INSTALLER B-45525VALVE GUIDE HONE HD-34751VALVE GUIDE CLEANING BRUSH HD-39782-ACYLINDER HEAD SUPPORT STAND HD-39786CYLINDER HEAD HOLDING FIXTURE HD-39847REAMER T-HANDLE...

Cylinder head — refacing valve seats
PART NUMBERTOOL NAME B-35758-52ACUTTER PILOT HD-34751VALVE GUIDE CLEANING BRUSH HD-35758-CNEWAY VALVE SEAT CUTTER SET HD-39786CYLINDER HEAD HOLDING FIXTURE Notes: Check that valve stem to valve guide clearance is correct before refacing. Refer to...

Cylinder head — assembly
PART NUMBERTOOL NAMEHD-34736-BVALVE SPRING COMPRESSOR 1. Apply a liberal amount of SCREAMIN' EAGLE ASSEMBLY LUBE to the valve stem. 2. See Figure 3-71. Insert valve (1) into valve guide (3) and bottom valve on valve seat (2). 3. See Figure 3-67....

Cylinder and piston — cleaning, inspection and repair
PART NUMBERTOOL NAME HD-33446-86TORQUE PLATE BOLTS HD-33446-BCYLINDER TORQUE PLATES 1. Soak cylinder and piston in an aluminum-compatible cleaner/solvent until deposits are soft. Clean with a brush. Blow off loosened carbon and dirt particles. Wash...

Cylinder and piston — connecting rod bushings
PART NUMBERTOOL NAME HD-35102WRIST PIN BUSHING HONE HD-39964REAMER LUBRICANT HD-94800-26ACONNECTING ROD BUSHING REAMER HD-95952-33CCONNECTING ROD CLAMPING TOOL HD-95970-32DCONNECTING ROD BUSHING REMOVER/INSTALLER Removing upper connecting rod...

Engine top end overhaul: assembly
This section describes assembling the top end of the engine, from the cylinder deck up. If the engine crankcase has been disassembled for repair, it must be assembled before assembling the top end of the engine. See 3.22 BOTTOM END OVERHAUL:...

Engine bottom end overhaul: disassembly
This section describes disassembling the bottom end of the engine. If engine overhaul requires disassembly of crankcases, remove engine from vehicle. See 3.10 REMOVING ENGINE FROM CHASSIS. Then disassemble top end of engine. See 3.13 TOP END...

Gearcase: XL models
Bushing inspection and removal: XL only PART NUMBERTOOL NAMEHD-95760-69ABUSHING AND BEARING PULLER Note. The camshaft and pinion gear shafts are supported by bushings in both the cover and the crankcase. 1. See Figure 3-114. Measure each bushing and...

Crankcase — disassembly and assembly
When replacing the connecting rod and flywheel assembly, the pinion shaft bearing, or the sprocket shaft bearing, inspect and make repairs to the cylinder heads, the cylinders, the gear case and the transmission. Perform a complete engine overhaul....

Engine bottom end overhaul: assembly
Crankcase PART NUMBERTOOL NAME B-45520GEAR DETENT ASSEMBLY AID B-45655CRANKCASE BEARING REMOVER/INSTALLER B-45676-ASPROCKET SHAFT SEAL/SPACER INSTALLER HD-42326-BCRANKSHAFT GUIDE TOOL HD-42579-6SPROCKET SHAFT ADAPTER HD-42579-ASPROCKET SHAFT...