Periodic service of motorcycle Harley Sportster XL1200 (2012-2023)

Fastener torque values in this chapter
The table below lists torque values for all fasteners presented in this chapter. FASTENERTORQUE VALUENotes: Air cleaner cover screw36-60 in·lbs4.1-6.8 Nm1.5 MAINTENANCE SCHEDULE, General Air cleaner cover screw36-60 in·lbs4.1-6.8 Nm1.7 AIR FILTER,...

Servicing a new motorcycle
Warning! Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or...

Fuel and oil for motorcycle
Fuel Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump. Refer to Table 1-1. Warning! Avoid spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel...

Bulb requirements chart
Table 1-3. Bulb chart LAMPDESCRIPTION(ALL LAMPS 12 V)BULBS REQUIREDCURRENT DRAW (AMPERAGE)HARLEY-DAVIDSON PART NUMBER HeadlampHigh beam/low beam15.0/4.5868329-03 Position lamp international10.3253436-97 Indicator lamp moduleAll models***--LED...

Maintenance schedule of motorcycle
FASTENERTORQUE VALUE Air filter screw40-60 in·lbs4.5-6.8 Nm Air cleaner cover screw36-60 in·lbs4.1-6.8 Nm Battery negative terminal screw60-70 in·lbs6.8-7.9 Nm Brake master cylinder, front, reservoir cover screws9-17 in·lbs1.0-2.0 Nm Clutch...

Checking and adding oil
Removing and replacing oil filler cap 1. Park the motorcycle on level ground on the jiffy stand. 2. See Figure 1-1. Remove the filler cap from the oil tank. a. Press straight down on the filler cap and release. The cap will pop up. b. Pull up on the...

Changing oil and filter
PART NUMBERTOOL NAME HD-42311HARLEY-DAVIDSON OIL FILTER WRENCH HD-44067-AHARLEY-DAVIDSON OIL FILTER WRENCH FASTENERTORQUE VALUE Oil drain hose worm clamp6-10 in·lbs0.7-1.1 Nm Notice: Do not switch lubricant brands indiscriminately because some...

Air filter (XL models, except XL 1200V) — removal and installation
FASTENERTORQUE VALUE Air filter screw40-60 in·lbs4.5-6.8 Nm Air cleaner cover screw36-60 in·lbs4.1-6.8 Nm Removal 1. See Figure 1-9. Remove the two fasteners (1) and the trim insert (2) from the air cleaner cover (3). Figure 1-9. Air Filter Element:...

Air filter (XL 1200V models) — removal and installation
FASTENERTORQUE VALUE Air filter screw40-60 in·lbs4.5-6.8 Nm Air cleaner cover screw36-60 in·lbs4.1-6.8 Nm Removal 1. See Figure 1-10. Remove the fastener (1) from the air cleaner cover (2). Figure 1-10. Air Filter Element: XL 1200V: 1. Screw; 2....

Air filter (XR 1200X models) — removal and installation
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. Remove...

Cleaning air filter element
Warning! Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. Note. Do not tap the filter on a hard surface. 1. Wash the filter in warm...

Tires and wheels — air pressure
Warning! Be sure tires are properly inflated, balanced, undamaged, and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced, improperly inflated, overloaded or...

Tire replacement
Tread wear Warning! Replace tire immediately with a Harley-Davidson specified tire when wear bars become visible or only 1/32 in (0.8 mm) tread depth remains. Riding with a worn tire could result in death or serious injury. Harley-Davidson tires are...

Recommended motorcycle tires
Warning! Match tires, tubes, rim strips or seals, air valves and caps to the correct wheel. Contact a Harley-Davidson dealer. Mismatching can lead to tire damage, allow tire slippage on the wheel or cause tire failure, which could result in death or...

Wheel bearings
Note. Replace bearings in sets only. See 2.5WHEELS, Sealed Wheel Bearings. 1. Replace when bearings exceed end play service wear limit of 0.002 in (0.051 mm). 2. Inspect any time the wheels are removed. a. Inspectthe play of the wheel bearings by...

Wheel spokes
PART NUMBERTOOL NAME HD-48985SPOKE TORQUE WRENCH HD-94681-80SPOKE NIPPLE WRENCH FASTENERTORQUE VALUE Spoke nipple55 in·lbs6.2 Nm Warning! Spokes that are too tight can draw nipples through the rim or distort hub flanges. Spokes that are too loose...

Primary chain — free play adjustment
FASTENERTORQUE VALUE Primary chain adjuster locknut20-25 ft·lbs27.1-33.9 Nm Primary chain inspection cover90-120 in·lbs10.2-13.6 Nm Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before...

Transmission lubrication
FASTENERTORQUE VALUE Clutch inspection cover screws90-120 in·lbs10.3-13.6 Nm Primary chaincase drain plug14-30 ft·lbs19.0-40.7 Nm Clutch inspection cover screws90-120 in·lbs10.3-13.6 Nm Check lubricant level 1. Ride motorcycle until engine is warmed...

Clutch adjustment
FASTENERTORQUE VALUE Clutch inspection cover screws90-120 in·lbs10.3-13.6 Nm Clutch cable adjuster jamnut120 in·lbs13.6 Nm Release the clutch cable tension Warning! To prevent accidental vehicle start-up, which could cause death or serious injury,...

Drive belt and sprockets — inspection
General Warning! Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over bending can damage belt resulting in premature failure, which could cause loss of control and death or serious...

Throttle control — lubrication and adjustment
Cable inspection and lubrication FASTENERTORQUEVALUESwitch housing screw35-45 in·lbs4.0-5.1 Nm 1. Release the throttle cable tension. See 1.13 THROTTLE CONTROL, Cable Adjustment. 2. See Figure 1-35. Remove screws (1) to separate the upper switch...

Cable and chassis lubrication
General Inspect and lubricate the following items according to 1.5 MAINTENANCE SCHEDULE. Front brake hand lever Clutch hand lever Throttle control cables Throttle control grip sleeve Clutch cable Foot shift lever pivot (if applicable) Rear brake...

Brake lines maintenance
General The front and rear brakes are fully hydraulic disc brake systems that require little maintenance. Warning! Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which...

Brake pads and discs: XL models — inspection
Inspection Brake pads Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid...

Brake pads and discs: XR 1200X — inspection
Inspection Brake pads Warning! Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. Caution! Direct contact of DOT 4 brake fluid with eyes can cause...

Spark plugs maintenance — removal, installation and inspection
Removal Warning! Disconnecting spark plug cable with engine running can result in electric shock and death or serious injury. Note. Allow the engine to cool before servicing. 1. Disconnect spark plug cables. 2. Remove spark plugs. Inspection Note....

Steering head bearings
Fall-away FASTENERTORQUE VALUE Fork stem pinch bolt30-35 ft·lbs40.7-47.5 Nm Fork bracket pinch screw30-35 ft·lbs40.7-47.5 Nm Measurement 1. Raise the front wheel off the floor. 2. Remove the components that interfere with front fork swing. 3....

Checking torques on fasteners
Inspect critical fasteners at the scheduled service intervals. Replace any damaged or missing fasteners. 1. Attempt to turn the fastener using a torque wrench set to the minimum torque specification for that fastener. Refer to Table 1-20. a. If the...

Engine mounts and stabilizer links — inspection
Inspection Check engine mounts and stabilizer links as follows: 1. See Figure 1-66. Check for cracks ortears in engine mount isolator rubber (17, 18). 2. Check for lateral movement at each end of the three stabilizer links (8). Any lateral movement...

Battery maintenance
General Warning! Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. Warning!...

Exhaust system leak check
1. Check entire exhaust system for loose or missing fasteners, damaged pipe clamps or brackets, and obvious signs of leakage (carbon tracks at pipe joints, etc.). 2. Check for loose or damaged heat shields. Repair or replace as necessary. 3. Check...

Checking wheel alignment
PART NUMBERTOOL NAMEHD-48856-AAXLE ALIGNMENT PLUGS FASTENERTORQUE VALUEAxle, rear, nut95-105 ft·lbs129-142 Nm Checking wheel alignment Warning! Check vehicle alignment according to following procedures. Incorrect alignment can adversely affect...

Suspension adjustments
Front fork: XR 1200X Warning! Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. Notice: Compression and rebound adjusting valves may be damaged if too much force is used...

Headlamp alignment
Warning! The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. Note. Adjust the...

Placing motorcycle in storage
PART NUMBERTOOL NAME98716-87ASTORAGE COVER Warning! Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive,...

Metric conversion table
Table D-1. Metric conversions Millimeters to inches (mm x 0.03937 = in) mminmminmminmmin .1.003925.9842582.283913.582 .2.0078261.024592.323923.622 .3.0118271.063602.362933.661 .4.0157281.102612.401943.701 .5.0197291.142622.441953.740...

Fluid volume conversions
United states system Unless otherwise specified, all fluid volume measurements in this service manual are expressed in United States (U.S.) units-of-measure. See below: 1 pint (U.S.) = 16 fluid ounces (U.S.) 1 quart (U.S.) = 2 pints (U.S.) = 32 fl....

Torque conversions
United states system The U.S. units of torque, foot pounds and inch pounds, are used in this service manual. To convert units, use the following equations: foot pounds (ft·lbs) X 12.00000 = inch pounds (in·lbs). inch pounds (in·lbs) X 0.08333 = foot...

Acronyms and abbreviations
Table E-1. Acronyms and abbreviations ACRONYM OR ABBREVIATIONDESCRIPTION AAmperes AATAmbient air temperature ABSAnti-lock braking system ACAlternating current ACCAccessory position on ignition switch ACRAutomatic compression release AGMAbsorbed...

Tools used in this manual
PART NUMBERTOOL NAMENotes: 94448-82BSHOCK ADJUSTMENT SPANNER1.25 SUSPENSION ADJUSTMENTS, Shock Absorber Preload: All Models 98716-87ASTORAGE COVER1.27 STORAGE, Placing in Storage 99863-01AGLOBAL BATTERY CHARGER1.22 BATTERY MAINTENANCE, Storage...

All torque values for motorcycle repair
FASTENERTORQUE VALUENotes: Air box to bracket fasteners: XR 1200X36-60 in·lbs4.1-6.7 Nm4.5 FUEL TANK: XR 1200X, Installing Fuel Tank Air cleaner breather screw84-120 in·lbs9.5-13.6 Nm4.3 AIR CLEANER ASSEMBLY, XL Models except XL 1200V Air cleaner...