| PART NUMBER | TOOL NAME |
| HD-45967 | SHOP DOLLY |
| HD-45968 | FAT JACK |
| HD-46284 | ENGINE HOOK |
| FASTENER | TORQUE VALUE | |
| Isolator mount, front, screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Isolator mount, rear, screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Fork, rear, pivot/engine mount bolt | 60-70 ft·lbs | 81.4-95.0 Nm |
| Engine mount, front, bolt | 95-105 ft·lbs | 129 -142 Nm |
| Retainer plate, lower front, fastener | 45-50 ft·lbs | 61.0-67.8 Nm |
| Stabilizer link, lower, frame bracket, front, mounting screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Stabilizer link cylinder head bracket | 55-65 ft·lbs | 74.6-88.2 Nm |
| Stabilizer link, upper front, frame bracket mounting screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Stabilizer link screw | 25-35 ft·lbs | 33.9-47.5 Nm |
| Footrest mount fastener | 45-50 ft·lbs | 61.0-67.8 Nm |
| Shift linkage pivot bolt | 120-180 in·lbs | 13.6-20.3 Nm |
| Ignition switch mounting screw | 34-45 in·lbs | 4.0-5.1 Nm |
| Oil cooler fastener: XR 1200X | 36-60 in·lbs | 4.1-6.8 Nm |
| Induction module coverto cylinder head fastener: XR 1200X | 20-24 ft·lbs | 27.1-32.5 Nm |
| Induction module coverto induction module fastener: XR 1200X | 84-108 in·lbs | 9.5-12.2 Nm |
| Induction module coverto wire form fastener: XR 1200X | 84-108 in·lbs | 9.5-12.2 Nm |
| Fuel tank mounting screw | 15-20 ft·lbs | 20.4-27.1 Nm |
| Footrest mount fastener | 45-50 ft·lbs | 61.0-67.8 Nm |
| Siren/canister bracket rear brake line fastener | 17-22 ft·lbs | 23.0-29.8 Nm |
| Shock absorber mounting bolt | 45-50 ft·lbs | 61.0-67.8 Nm |
| Sprocket cover, rear screw | 30-33 ft·lbs | 40.7-44.8 Nm |
| Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
| Axle, rear, nut | 95-105 ft·lbs | 129-142 Nm |
1. See Figure 3-26. Verify pivot shaft (4) and rear pivot lockplate (5) are mounted on engine mounting boss at rear of engine. Position right rear isolator (7) on pivot shaft on rear of engine. Do not install left rear isolator at this time.
2. Position right front isolator (8) on front of engine. Do not install left front isolator at this time.
3. Attach ENGINE HOOK (Part No. HD-46284) and engine hoist to engine.
4. Lift engine and swing assembly into chassis from left side. Swing front of engine in first.
5. Install left rear isolator (7) over pivot shaft (4). Install rear isolator mount (2) over left rear isolator and attach to frame with two screws (3). Do not tighten screws at this time.
6. Raise or lower engine until right front isolator lines up with mounting hole in frame.
7. Install left front isolator (8) and front isolator mount (9) to left side of frame with two screws (11). Do not tighten screws at this time.
8. Insert front engine mount bolt (10) from left side, through isolators and crankcase boss. Place nut (12) on bolt but do not tighten at this time.
9. Tighten two screws (11) securing front isolator mount (9) to 25-35 ft·lbs (33.9-47.5 Nm).
10. Tighten two screws (3) securing rear isolator mount (2) to 25-35 ft·lbs (33.9-47.5 Nm).
11. Using new hose clamp, install oil tank vent hose at oil tank. See 3.24 OIL TANK.
12. Install rear fork with pivot/engine mount bolts (1). Tighten to 60-70 ft·lbs (81.4-95.0 Nm).
13. Tighten front engine mount bolt (10) and nut (12) to 95105 ft·lbs (129-142 Nm).
14. Install J-clip (14) to each side of frame. Tighten fasteners (13) to 45-50 ft·lbs (61.0-67.8 Nm).
15. Remove ENGINE HOOK (Part No. HD-46284).
16. With the aid of a FAT JACK (Part No. HD-45968), remove motorcycle from SHOP DOLLY (Part No. HD-45967).
17. See Figure 3-24. Install lower front stabilizer link and frame bracket:
- a. Install lower frame bracket (2) with stabilizer link (1). Secure with screws (4) and washers (5). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
- b. Install screw (3) securing stabilizer link to engine crankcase boss. Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
18. See Figure 3-23. Install cylinder head stabilizer link bracket (1), upper stabilizer link (2) and upper frame bracket (3):
- a. Install the fasteners (6), lockwashers (7) and the stabilizer cylinder head bracket (1). Tighten to 55-65 ft·lbs (74.6-88.2 Nm).
- b. Install upper frame bracket with stabilizer link, horn bracket (9) (models with front mounted horn), screws (5) and washers (8). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
- c. Install screw (4) securing stabilizer link to cylinder head bracket (1). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
19. See Figure 3-22. Install spacer (5), rear stabilizer link (1), grounding strap (2) and screws (3, 4). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
20. See Figure 3-25. Install shift lever and rider left footrest and mounting bracket assembly. Tighten fasteners (2) to 45-50 ft·lbs (61.0-67.8 Nm).
21. Connect shift linkage to transmission shift lever. Tighten fastener (1) to 120-180 in·lbs (13.6-20.3 Nm).
22. Install induction module and intake manifold. See 4.9 INDUCTION MODULE: XR 1200X.
23. Rotate backbone wire harness caddy down into place.
24. See 6.13 IGNITION COIL. Position ignition coil and bracket on backbone caddy behind steering head. Place front wire harnesses, mounting boss from right wire harness caddy and throttle cables between coil bracket uprights.
25. Plug ignition coil harness connector [83] into coil. Mount ignition switch to coil bracket with screw. Tighten to 34-45 in·lbs (4.0-5.1 Nm). Secure right wire harness caddy to coil bracket with new push-in fastener.
26. Connect clutch cable to clutch lever on handlebar. Secure cable to lower oil cooler mount. Attach clutch cable (along with wiring harness and front O2 sensor harness) to frame front left downtube with cable clips. Adjust clutch. See 2.29 CLUTCH CONTROL.
27. See Figure 3-21. Install the oil coolerto the frame mounts. Tighten fasteners (1) to 36-60 in·lbs (4.1-6.8 Nm).
28. Plug the following electrical connectors into the engine:
- a. Engine Temperature (ET) sensor connector [90]. Secure sensor harness to H-bracketwith barbed cable strap. To avoid damage to sensor during vehicle operation, secure harness with a loop between sensor and H-bracket. Press barbed prong of cable strap into hole in boss in H-bracket. See 4.7 ENGINE TEMPERATURE (ET) SENSOR.
- b. Starter relay wire (GN) at starter motor. See 6.10 STARTER.
- c. Vehicle speed sensor (VSS) connector [65]. See 6.25 VEHICLE SPEED SENSOR (VSS).
- d. Neutral indicator switch connector [136]. See 6.26 NEUTRAL INDICATOR SWITCH.
- e. Alternator AC connector [46]. Secure to right downtube with a cable strap. See 6.23 VOLTAGE REGULATOR.
- f. Connect voltage regulator DC connector [77] and secure to frame cross member with cable strap. See 6.23 VOLTAGE REGULATOR.
- g. Crank position (CKP) sensor connector [79]. See 6.22 CRANK POSITION SENSOR (CKP).
- h. Oil pressure switch connector [120]. See 6.31 OIL PRESSURE SWITCH.
- i. Spark plug wires.
- j. Ground wire at powertrain ground stud on crankcase.
29. See 4.9 INDUCTION MODULE: XR 1200X and plug the following into the induction module:
- a. TPS [88].
- b. IAC [87].
- c. TMAP [80].
- d. Fuel injector connectors [84], [85].
30. Install and connect jiffy stand sensor. See 6.29 JIFFY STAND SENSOR (JSS): INTERNATIONAL MODELS.
31. Install and connect horn. See 6.32 HORN.
32. See Figure 3-18. Install induction module cover. Secure TPS harness to cover during installation.
- a. Tighten fasteners (2) to 20-24 ft·lbs (27.1-32.5 Nm).
- b. Tighten fastener (1) to 84-108 in·lbs (9.5-12.2 Nm).
- c. Tighten fastener (3) to 84-108 in·lbs (9.5-12.2 Nm).
33. Install air cleaner assembly on induction module. Connect breather hoses to rocker box fittings. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
34. EVAP Controlled Models: Install EVAP purge hose on induction module. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
Warning! 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.
35. Install fuel tank. Tighten screws to 15-20 ft·lbs (20.4-27.1 Nm). Attach quick-connect fitting on fuel line to fuel tank fitting. Gently tug on quick-connect fitting to make sure it is securely locked in place. See 4.5 FUEL TANK: XR 1200X.
36. Secure air filter assembly to fuel tank with two screws.
37. Install oil hoses.
- a. Feed oil drain hose down through drain hose sleeve in rear of engine crankcase.
- b. Using new hose clamps, install oil tank feed, drain and return hoses onto oil tank.
- c. Install drain plug in end of drain hose.
- d. Secure with worm drive clamp. Tighten clamp securely. See 3.24 OIL TANK.
38. See Figure 3-20. Install right rider footrest assembly and rear master cylinder assembly. Tighten fasteners (1) to 45-50 ft·lbs (61.0-67.8 Nm).
39. See Figure 3-19. Secure brake line and siren/canister mount plate to frame and rear fork. Tighten fasteners (1) to 17-22 ft·lbs (23.0-29.8 Nm). Connect rear stop lamp switch connectors.
Note. Verify that the EVAP canister mounting hardware does not contact the rear stabilizer ground strap.
40. Install these parts if present:
- a. EVAP Controlled Models: Install EVAP canister and hoses. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
- b. All other Models: Install siren if equipped. See 6.30 SECURITY SYSTEM/OPTIONAL SIREN.
41. If removed, install transmission sprocket. See 5.15 TRANSMISSION SPROCKET.
42. Install rear drive belt and hand-tighten rear axle. Final belt adjustment will be performed later. See 5.6 DRIVE BELT.
43. Secure right shock absorber to rear fork. Tighten to 4550 ft·lbs (61.0-67.8 Nm).
44. Install belt guard and debris deflector.
45. Install sprocket cover. Tighten sprocket cover screws.
- a. Tighten rear (larger) screw to 30-33 ft·lbs (40.7-44.8 Nm).
- b. Tighten forward and lower (smaller) screws to 80-120 in·lbs (9.0-13.6 Nm).
46. Install exhaust pipes and mufflers. See 4.14 EXHAUST SYSTEM: XR 1200X.
Note. It is important to route and secure the front O2 sensor harness correctly to prevent premature harness failure. See 4.12 OXYGEN (O2) SENSOR, Installation.
47. Plug in O2 sensor connectors [137], [138]. Make sure each O2 sensor harness is routed and secured correctly. See 4.12 OXYGEN (O2) SENSOR, Installation.
48. Fill oil tank. See 1.6 ENGINE OIL AND FILTER, Changing Oil and Filter.
49. Fill primary chaincase/transmission with FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT. See 1.10 TRANSMISSION LUBRICANT.
50. Adjust belt tension and rear wheel alignment. Tighten rear axle nut to 95-105 ft·lbs (129-142 Nm). Install new E-clip. See 1.24 WHEEL ALIGNMENT.
51. Connect battery. See 1.22 BATTERY MAINTENANCE.
52. Install left side cover. See 2.18 LEFT SIDE COVER.
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.
53. Install seat.