PART NUMBER | TOOL NAME |
HD-45967 | SHOP DOLLY |
HD-45968 | FAT JACK |
HD-46284 | ENGINE 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 result in death or serious injury.
1. Position vehicle upright. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.5 FUEL TANK: XR 1200X.
2. Remove seat.
3. Remove left side cover. See 2.18 LEFTSIDE COVER.
Warning! Prevent accidental vehicle start-up, which could cause death or serious injury. First disconnect negative (-) battery cable at engine and then positive (+) cable from battery.
4. Disconnect negative (-) battery cable from ground stud on crankcase. Disconnect positive (+) battery cables at battery. Remove battery. See 1.22 BATTERY MAINTENANCE.
5. Drain primary chaincase/transmission fluid. See 1.10 TRANSMISSION LUBRICANT.
6. Drain oil tank. Do not install drain plug back in end of drain hose at this time. See 1.6 ENGINE OIL AND FILTER.
7. See Figure 3-18. Remove fasteners (1, 2, 3) and remove induction module cover. Cut cable strap securing TPS harness to side plate.
![](https://motoinstruction.ru/img/harley/12/117877.jpg)
Figure 3-18. Induction module cover: XR 1200X: 1. Fastener, wire form; 2. Fastener, to induction module; 3. Screws (2)
8. Disconnect O2 sensor connectors [137], [138] and remove exhaust pipes and mufflers as an assembly. See 4.14 EXHAUST SYSTEM: XR 1200X.
9. Remove these parts if present:
- EVAP Controlled Models: Remove EVAP canister and disconnect hoses. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
- All other Models: Remove siren if equipped. See 6.30 SECURITY SYSTEM/OPTIONAL SIREN.
10. See Figure 3-19. Remove two fasteners (1) retaining siren/canister mount plate and brake line (2) retainer.
![](https://motoinstruction.ru/img/harley/12/117878.jpg)
Figure 3-19. Siren/canister mount plate and brake line: 1. Fastener, siren/canister mount; 2. Rear brake line
11. Remove three screws securing sprocket cover to engine case. Remove sprocket cover.
12. Remove belt guard and debris deflector from rear fork.
13. Remove fastener securing right shock absorber to the rear fork.
14. Loosen rear axle nut and move rear axle all the way forward. Tighten axle nut enough to hold the axle and wheel in position in the rear fork. Remove rear drive belt. See 5.6 DRIVE BELT.
15. Remove transmission sprocket only if transmission or engine are to be disassembled. See 5.15 TRANSMISSION SPROCKET.
16. Disconnect rear stop lamp switch connectors [121].
17. Remove rear brake line from clamps at the bottom of left rear fork.
Note. When securing rear master cylinder out of the way in the next step, make sure to keep the reservoir upright. If the reservoir is allowed to hang upside down, air bubbles could be introduced into the rear master cylinder. If this happens, the rear brake must be bled to remove all air from the hydraulic brake system.
18. See Figure 3-20. Remove fasteners (1) and remove rider's right footrest including master cylinder assembly and rear brake linkage. Be careful not to bend or kink metal brake line and remove assembly out left side of motorcycle. Tie assembly, with master cylinder upright, out of the way.
![](https://motoinstruction.ru/img/harley/12/117879.jpg)
Figure 3-20. Right footrest and rear master cylinder: 1. Fastener, footrest mount (2); 2. Footrest and master cylinder bracket
19. Disconnect oil tank feed, drain and return hoses from oil tank. Pull drain hose up through drain hose sleeve in rear of engine crankcase and remove hose from vehicle. See 3.24 OIL TANK.
20. Unplug horn connectors and remove horn from horn bracket. See 6.32 HORN.
21. Remove fasteners securing air cleaner to fuel tank. Drain and remove fuel tank. See 4.5 FUEL TANK: XR 1200X.
22. Remove air cleaner from induction module as an assembly. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
23. EVAP Controlled Models: Remove EVAP purge hose from induction module. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
24. Unplug the following connectors from the induction module:
- a. Fuel injector connectors [84], [85].
- b. Temperature/Manifold absolute pressure (TMAP) sensor connector [80].
- c. Idle Air Control (IAC) connector [87].
- d. Throttle Position (TPS) connector [88].
25. Unplug the following electrical connectors from the engine:
- a. Ground wire at powertrain ground stud on crankcase.
- b. Spark plug wires.
- c. Oil pressure switch connector [120]. See 6.31 OIL PRESSURE SWITCH.
- d. Crank position (CKP) sensor connector [79]. See 6.22 CRANK POSITION SENSOR (CKP).
- e. Alternator AC connector [46] and DC connector [77]. See 6.23 VOLTAGE REGULATOR.
- f. Neutral indicator switch connector [136]. See 6.26 NEUTRAL INDICATOR SWITCH.
- g. Vehicle speed sensor (VSS) connector [65]. See 6.25 VEHICLE SPEED SENSOR (VSS).
- h. Starter relay wire (GN) at starter motor. See 6.10 STARTER.
- i. Engine Temperature (ET) sensor connector [90]. Cut and remove barbed cable strap securing sensor harness to H-bracket. See 4.7 ENGINE TEMPERATURE (ET) SENSOR.
26. If equipped, disconnect jiffy stand sensor connector [133] and remove sensor. See 6.29 JIFFY STAND SENSOR (JSS): INTERNATIONAL MODELS.
27. Disconnect clutch cable and remove from clutch lever on left handlebar. Remove cable from oil cooler mount and clips securing clutch cable to left front downtube. See 2.29 CLUTCH CONTROL.
28. See Figure 3-21. Remove oil cooler fasteners (1) from frame mounts (2) and remove oil cooler. It is not necessary to disconnect the oil hoses attached to the oil cooler. Tie oil cooler to engine.
![](https://motoinstruction.ru/img/harley/12/117880.jpg)
Figure 3-21. Oil cooler mounts: 1. Fastener (2); 2. Oil cooler mount (2)
29. Remove ignition coil. See 6.13 IGNITION COIL.
30. Position ignition switch out of the way.
31. Remove induction module, leaving cables attached. Secure induction module assembly and throttle cables out of the way. See 4.9 INDUCTION MODULE: XR 1200X.
32. See Figure 3-22. Remove screws (3, 4), grounding strap (2), stabilizer link (1) and spacer (5).
![](https://motoinstruction.ru/img/harley/12/117881.jpg)
Figure 3-22. Rear stabilizer link assembly (typical): 1. Stabilizer link; 2. Grounding strap; 3. Screw; 4. Screw; 5. Spacer
33. See Figure 3-23. Remove upper stabilizer link (2), cylinder head stabilizer bracket (1) and the upper frame bracket (3):
- a. Remove screw (4) securing stabilizer link to cylinder head bracket (1).
- b. Remove screws (5) and washers (8). Remove horn bracket (9) and upper stabilizer link bracket (3) with stabilizer link.
- c. Remove screws (6) and lock washers (7) and the cylinder head bracket (1).
![](https://motoinstruction.ru/img/harley/12/117882.jpg)
Figure 3-23. Upper front stabilizer link assembly: 1. Engine bracket; 2. Upper stabilizer link; 3. Upper frame bracket; 4. Screw; 5. Screw (2); 6. Screw (2); 7. Lockwasher (2); 8. Washer (2); 9. Horn bracket (front mount models)
34. See Figure 3-24. Remove lower stabilizer link (1) and lower frame bracket (2) as an assembly:
- a. Remove screw (3) securing stabilizer link to engine crankcase boss.
- b. Remove screws (4), washers (5) and lower frame bracket with stabilizer link.
![](https://motoinstruction.ru/img/harley/12/117883.jpg)
Figure 3-24. Lower front stabilizer link assembly (typical): 1. Lower stabilizer link; 2. Lower frame bracket; 3. Screw (2); 4. Screw (2); 5. Washer (2)
35. See Figure 3-25. Remove fastener (1) and disconnect shift linkage from transmission shift lever.
![](https://motoinstruction.ru/img/harley/12/117884.jpg)
Figure 3-25. Left footrest and shift linkage: 1. Fastener, shift linkage; 2. Fastener, footrest mount (2)
36. Remove fasteners (2) and remove rider left footrest and mounting bracket assembly along with foot shift lever and linkage.
37. With the aid of a FAT JACK (Part No. HD-45968), support motorcycle on SHOP DOLLY (Part No. HD-45967).
38. See Figure 3-26. Remove fasteners (13) and j-clip (14) from each side of frame.
![](https://motoinstruction.ru/img/harley/12/117885.jpg)
Figure 3-26. Engine mount/isolator components (typical): 1. Bolt (2); 2. Rear isolator mount; 3. Screw (2); 4. Rear fork pivot shaft; 5. Rear pivot lockplate; 6. Screw (3); 7. Rear isolator (2); 8. Front isolator (2); 9. Front isolator mount; 10. Front mount bolt; 11. Screw (2); 12. Nut; 13. Screw; 14. J-clip (2)
39. Loosen, but do not remove, two front isolator mounting bracket screws (11) on left side of engine.
40. Loosen, but do not remove, two rear isolator mounting bracket screws (3) on left side of engine.
41. Attach ENGINE HOOK (Part No. HD-46284) and engine hoist. Carefully raise engine enough to relieve pressure from mounting bolts.
42. Remove front engine mount bolt (10) and nut (12).
43. Remove two screws (11) and front isolator mount (9).
44. Remove two rear engine mount/rear fork pivot bolts (1). Pull rear fork back until fork pivot bosses clear the frame.
45. Remove oil tank vent hose from oil tank. See 3.24 OIL TANK.
46. Remove two screws (3) and rear isolator mounting bracket (2) from frame.
47. Rotate backbone electrical caddy to the left to allow room to lift the engine.
48. Lift engine as necessary and swing assembly out from left side of chassis, rear of engine first. Remove engine from chassis.