Elements of transmission motorcycle 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 Nm5.6 DRIVE BELT, Drive Belt: XL Models Axle, rear, nut95-105 ft·lbs129-142 Nm5.6 DRIVE BELT, Drive Belt:...

Specifications of transmission
Table 5-1. Sprocket teeth DRIVEITEMNUMBER OF TEETH XL 883 MODELSXL 1200 MODELSXR1200X U.S.WORLDU.S.WORLDU.S./WORLD PrimaryEngine3434383834 Clutch5757575757 FinalTransmission2929293028 Rear wheel6868686868 Table 5-2. Overall drive ratios GEARXL 883...

Primary cover — removal and installation
Removal Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. 1. Disconnect the negative (-) battery cable from the engine stud on the back...

Primary drive and clutch: XL models — removal, installation, disassembly and assembly
Table 5-4. Clutch troubleshooting SYMPTOMCHECK ORDERCAUSEREMEDY Clutch slips1Incorrect clutch release adjustmentCheck and adjust clutch release mechanism. 2Worn clutch platesCheck service wear limits. Replace plates. Clutch drags1Incorrect clutch...

Primary drive and clutch: XR 1200X models
Removal PART NUMBERTOOL NAME HD-38362SPORTSTER 5-SPEED SPROCKET LOCKING LINK HD-46283PRIMARY DRIVE LOCKING TOOL Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable...

Drive belt — removal and installation
Drive belt handling See Figure 5-36. Do not exceed 5 in (127 mm) forward bend (1). Do not exceed 10 in (254 mm) reverse bend (2). Do not twist (3). Do not crimp, pinch or kink (4). Do not pry (5). Figure 5-36. Drive belt handling Drive belt: XL...

Transmission power flow
See Figure 5-44. The transmission is a five-speed constantmesh type housed in an extension of the crankcase. The transmission permits the rider to vary the ratio of engine speed-to-rear driving wheel speed in order to meet the varying conditions of...

Case disassembly for transmission removal
The rear compartment of the left and right crankcase halves form the transmission case. Servicing of transmission components requires removing the engine and disassembling (splitting) the crankcase. Engine removal and disassembly PART NUMBERTOOL...

Transmission removal and disassembly
Transmission removal from left crankcase PART NUMBERTOOL NAME B-43895-1REMOVER B-43985TRANSMISSION REMOVAL AND INSTALLATION TOOL Note. See Figure 5-55. Shifter design allows for one common part number for both countershaft shifter forks (4, 5). As...

Transmission assembly
Mainshaft assembly PART NUMBERTOOL NAMEJ-5586-ARETAINING RING PLIERS Warning! Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause...

Main drive gear and bearing — removal, installation, disassembly and assembly
Note. See Figure 5-64. Main drive gear (2) removal requires replacement of the main drive gear bearing (7 or 14). Gear removal procedure destroys bearing's inner race. Figure 5-64. Main drive gear and bearing assembly: 1. Needle bearing (2); 2. Main...

Transmission right case bearings — removal and installation
Removal PART NUMBERTOOL NAME HD-95760-69ABUSHING AND BEARING PULLER HD-95765-69A1/2 INCH COLLET Split crankcases. See 5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL. Countershaft needle bearing See Figure 5-86. From inside transmission case use a...

Transmission left case bearings — removal and installation
Removal PART NUMBERTOOL NAMEPR-36SNAP-ON SNAP RING PLIERS Mainshaft and countershaft bearings 1. Split crankcases. See 5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL. 2. Disassemble transmission. See 5.9 TRANSMISSION REMOVAL AND DISASSEMBLY. a....

Transmission installation
Before reinstalling transmission and reassembling crankcase halves, perform any necessary engine overhaul procedures. See 3.9 BOTTOM END SERVICE and 3.8 TOP END SERVICE. Installation PART NUMBERTOOL NAME B-43985TRANSMISSION REMOVAL AND INSTALLATION...

Transmission sprocket — removal and installation
Removal PART NUMBERTOOL NAME HD-42310-45ENGINE CRADLE HD-46282-1AFINAL DRIVE SPROCKET HOLDING TOOL REACTION ADAPTER HD-46282-AFINAL DRIVE SPROCKET HOLDING TOOL HD-46288MAINSHAFT LOCKNUT WRENCH Warning! To prevent accidental vehicle start-up, which...