Maintenance schedule of motorcycle (Harley Sportster XL1200)

0

FASTENER	TORQUE VALUE
Air filter screw	40-60 in·lbs	4.5-6.8 Nm
Air cleaner cover screw	36-60 in·lbs	4.1-6.8 Nm
Battery negative terminal screw	60-70 in·lbs	6.8-7.9 Nm
Brake master cylinder, front, reservoir cover screws	9-17 in·lbs	1.0-2.0 Nm
Clutch inspection cover screws	90-120 in·lbs	10.3-13.6 Nm
Handlebar clamp screw	12-18 ft·lbs	16.3-24.4 Nm
Switch housing screw	35-45 in·lbs	4.0-5.1 Nm
Fuel pump module mounting screw	40-45 in·lbs	4.5-5.1 Nm
Chain tensioner nut	20-25 ft·lbs	27.1-33.9 Nm
Primary chain inspection cover	90-120 in·lbs	10.2-13.6 Nm
Primary chaincase drain plug	14-30 ft·lbs	19.0-40.7 Nm
Spark plug	12-18 ft·lbs	16.3-24.4 Nm
Spark plug	12-18 ft·lbs	16.3-24.4 Nm
Spoke nipple	55 in·lbs	6.2 Nm

At each regular service interval, perform the required maintenance. Refer to Table 1-4.

Use the quick reference maintenance chart for torque values, lubricants or cross references to maintenance procedures. Refer to Table 1-5.

Use the lubricants, greases and sealants table to identify maintenance supplies. Refer to Table 1-6.

Table 1-4. Regular service intervals: 2013 Sportster models

Item serviced

Procedure

1000 mi 1600 km

5000 mi 8000 km

10000 mi 16000 km

15000 mi 24000 km

20000 mi 32000 km

25000 mi 40000 km

30000 mi 48000 km

35000 mi 56000 km

40000 mi 64000 km

45000 mi 72000 km

50000 mi 80000 km

Notes:

Engine oil and filter

Replace

X

X

X

X

X

X

X

X

X

X

X

3,7

Oil lines and brake system

Inspect for leaks, contactorabrasion

X

X

X

X

X

X

X

X

X

X

X

1,3

Air cleaner

Inspect, service as required

X

X

X

X

X

X

X

X

X

X

7

Tires

Check pressure, inspect tread

X

X

X

X

X

X

X

X

X

X

X

3

Wheel spokes (if equipped)

Check tightness

X

X

X

X

X

1,5,7

Primary chain

Check adjustment

X

X

X

X

X

X

X

X

X

X

X

Transmission lubricant

Replace

X

X

X

X

X

X

7

Clutch

Check adjustment

X

X

X

X

X

X

X

X

X

X

X

1,7

Drive belt and sprockets

Inspect, adjust belt

X

X

X

X

X

X

X

X

X

X

X

1

Throttle, brake and clutch controls

Check, adjust and lubricate

X

X

X

X

X

X

X

X

X

X

X

1

Jiffy stand

Inspect and lubricate

X

X

X

X

X

X

X

X

X

X

X

1

Fuel lines and fittings

Inspect for leaks, contactorabrasion

X

X

X

X

X

X

X

X

X

X

X

1,3

Fuel filter element

Replace

Replace every 100,000 mi (160,000 km).

1

Brake fluid

Inspect sight glass

X

X

X

X

X

X

X

X

X

X

X

4

Brake pads and discs

Inspect for wear

X

X

X

X

X

X

X

X

X

X

X

Front brake lever pin

Inspect

X

X

X

X

X

X

X

X

1,6

Front brake lever pin

Lubricate

X

X

1,6

Brake caliper pins

Inspect

X

X

X

X

X

X

X

X

1,6

Brake caliper pins

Lubricate

X

X

1,6

Brake caliper boots and bushings

Inspect

X

X

X

X

X

X

X

X

1,6

Brake caliper boots and bushings

Replace

X

X

1,6

Rear master cylinder outer boot

Inspect

X

X

X

X

X

X

X

X

X

X

1,6

Brake components

Replace brake rubber components in master cylinders and calipers

X

X

1,6

Brake components

Lubricate master cylinder pistons

X

X

1,6

Spark plugs

Replace

X

8

Electrical equipment and switches

Check operation

X

X

X

X

X

X

X

X

X

X

X

Front forks

Rebuild

X

1,9

Steering head bearings

Adjust

X

X

X

1,2

Rear fork bearings

Inspect every 30,000 mi (48,000 km)

1

Critical fasteners

Check tightness

X

X

X

X

X

X

1

Engine mounts and stabilizer links

Inspect

X

X

X

X

X

1

Battery

Check battery and clean connections annually.

Exhaust system

Inspect for leaks, cracks, and loose or missing fasteners or heat shields

X

X

X

X

X

X

X

X

X

X

X

3,7

Road test

Verify component and system functions

X

X

X

X

X

X

X

X

X

X

X

Notes:

• 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.
• 2. Disassemble, lubricate and inspect every 30,000 mi (48,000 km).
• 3. Perform annually or at specified intervals, whichever comes first.
• 4. Replace DOT 4 hydraulic brake fluid and flush system every two (2) years.
• 5. Perform spoke tension check at 1000 mi (1600 km), 5000 mi (8000 km), 20,000 mi (32,000 km) services and every 15,000 mi (24,000 km) interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
• 6. Replace every four (4) years or at specified intervals, whichever comes first.
• 7. Perform maintenance more frequently in severe riding conditions (such as extreme temperatures, dusty environments, mountainous or rough roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality).
• 8. Replace every two (2) years or at specified intervals, whichever comes first.
• 9. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).

Table 1-5. Quick reference maintenance chart

ITEM SERVICED	SPECIFICATION	DATA
Air cleaner	See 1.7 AIR FILTER
	Air filter screw torque: XL Models	40-60 in·lbs (4.5-6.8 Nm)
	Air cleaner cover screw torque: XL Models	36-60 in·lbs (4.1-6.8 Nm)
Battery	Lubricant	Electrical Contact Lubricant
	Terminal screw torque	60-70 in·lbs (6.8-7.9 Nm)
Brake fluid reservoir level (Check sight glass. If fluid is low, remove reservoir cover and re-check.)	Brake fluid type	DOT 4 Brake Fluid
	Proper fluid level (front brake)	1/4 in (6.35 mm) from the top of the reservoir
	Proper fluid level (rear brake)	Upper fluid level in reservoir
	Front master cylinder reservoir cover screw torque	9-17 in·lbs (1.0-2.0 Nm)
Brake pad linings and discs	Minimum brake pad thickness	0.04 in (1.02 mm)
	Minimum brake disc thickness	See stamp on side of disc.
Clutch adjustment	Free play at adjuster screw	1/4 turn
	Free play at hand lever	1/16-1/8 in (1.6-3.2 mm)
	Clutch inspection cover screw torque	90-120 in·lbs (10.3-13.6 Nm)
Clutch and throttle cables	Lubricant	Harley Lube
	Handlebar clamp screw torque	12-18 ft·lbs (16.3-24.4 Nm)
	Switch housing screw torque	35-45 in·lbs (4.0-5.1 Nm)
Critical fasteners	See 1.20 CRITICAL FASTENERS.
Drive belt	Apply upward measurement force at midpoint of bottom belt strand.	10 lb (4.5 kg)
	Belt deflection with motorcycle on jiffy stand, belt and sprockets at ambient temperature (cold engine), without rider or luggage	XL 883L/XL 883N/XL 1200X/XL 1200V/XL 1200C/C ANV/XL 1200CP/XL 1200CA/XL 1200CB: 1/4-5/16 in (6.35-7.94 mm)
		XL 883R: 9/16-5/8 in (14.3-15.9 mm)
	Belt deflection measurement taken midway between rear sprocket and idler	XR 1200X: 1/4-3/8 in (6.4-9.5 mm)
Engine idle speed	Idle speed	950-1050 rpm
Engine mounts/isolators and stabilizers	See 2.26 FRONT ENGINE MOUNT/ISOLATOR, 2.27 REAR ENGINE MOUNT/ISOLATOR, and 2.25 STABILIZER LINKS.
Engine oil and filter	Oil capacity	2.8 qt (2.65 L)
	Filter	Hand tighten 1/2-3/4 turn after gasket contact.
Front fork oil: XL Models	Type	Type "E" Hydraulic Fork Oil
	Amount	See 2.19 FRONT FORK: XL MODELS, Assembly.
Front fork oil: XR 1200X	Type	Big Piston Fork Oil
	Amount	See 2.20 FRONT FORK: XR 1200X, Assembly.
Fuel filter	Fuel pump module mounting screw torque	40-45 in·lbs (4.5-5.1 Nm)
Primary chain tension	Deflection with hot engine	1/4-3/8 in (6.3-9.5 mm)
	Deflection with cold engine	3/8-1/2 in (9.5-12.7 mm)
	Chain tensioner nut torque	20-25 ft·lbs (27.1-33.9 Nm)
	Primary chain inspection cover screw torque	90-120 in·lbs (10.2-13.6 Nm)
Primary chain/transmission lubricant	Lubricant capacity	32 oz (946 mL)
	Primary chaincase drain plug torque	14-30 ft·lbs (19.0-40.7 Nm)
	Lubricant	Genuine Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant
Spark plugs: XL Models	Type	6R12
	Gap	0.038-0.043 in (0.96-1.09 mm)
	Torque	12-18 ft·lbs (16.3-24.4 Nm)
Sparkplugs: XR 1200X	Type	10R12X
	Gap	0.032-0.038 in (0.81-0.97 mm)
	Torque	12-18 ft·lbs (16.3-24.4 Nm)
Steering head bearings	Lubricant	Special Purpose Grease
Tire condition and pressure	XL 883L	Front: 36 psi (248 kPa) Rear: 42 psi (290 kPa)
	XL Models (except XL 1200X/C/C ANV/CP/CA/CB)	Front: 30 psi (207 kPa) Rear: 40 psi (276 kPa)
	XL 1200X/C/C ANV/CP/CA/CB	Front: 36 psi (248 kPa) Rear: 40 psi (275 kPa)
	XR 1200X	Front: 36 psi (248 kPa) Rear: 42 psi (290 kPa)
	Wear	Replace tire if 1/32 in (0.8 mm) or less of tread pattern remains.
Wheel spokes	Spoke nipple torque	55 in·lbs (6.2 Nm)

Table 1-6. Lubricants, greases, sealants

ITEM	PART NUMBER	PACKAGE
3M 847 Adhesive	021200-19718 *	5 oz tube
3M General Purpose Adhesive Remover		15 oz. aerosol
Anti-Seize Lubricant	98960-97	1 oz squeeze tube
Big Piston Fork Oil (Sportster XR only)	62600029	16 oz bottle
CCI #20 Brake Grease	42830-05	squeeze packet (included in master cylinder rebuild kit)
DOT 4 Brake Fluid	99953-99A	12 oz bottle
Dow Corning Moly 44 Grease	94674-99	2 cc packet
Electrical Contact Lubricant	99861-02	1 oz squeeze tube
Formula+ Transmission and Primary Chaincase Lubricant	99851-05	1 qt bottle
G40M Brake Grease	42820-04	squeeze packet
Genuine Harley-Davidson Extended Life Antifreeze and Coolant (V-Rod only)	99822-02	1 gal container
Genuine Harley-Davidson H-D 360 20W50 Motorcycle Oil	99816-2050/00QT	1 qt bottle
Harley-Davidson Adhesive (Griplock)	99839-95	10 g tube
Harley-Davidson High Performance Sealant - Gray	99650-02	1.9 oz squeeze tube
Harley-Davidson Leather Dressing	98261-91V	6 oz can
Harley-Davidson Seal Grease	11300005	1 oz tube
Harley® Lube	94968-09	1/4 oz needle dispenser
Hylomar Gasket and Thread Sealant	99653-85	3.5 oz tube
Loctite 222 Low Strength Threadlocker and Sealant (purple)	99811-97	6 mL tube
Loctite 243 Medium Strength Threadlocker and Sealant (blue)	99642-97	6 mL tube
	11100005	50 mL bottle
Loctite 246 Medium Strength/High Temperature Threadlocker (blue)
Loctite 262 High Strength Threadlocker and Sealant (red)	94759-99	6 mL tube
	11100006	50 mL bottle
Loctite 411 Prism Instant Adhesive
Loctite 420 Super Bonder Adhesive
Loctite 565 Thread Sealant	99818-97	6 mL tube
Loctite 770 Prism Primer
Loctite 7649 Cleaner/Primer	98968-99	1.75 oz bottle
RTV Silicone Sealer	99650-02	1.9 oz tube
Screamin' Eagle Assembly Lube	94971-09	4 oz bottle
Screamin' Eagle SYN3 Full Synthetic Motorcycle Lubricant 20W50	99824-03/00QT	1 qt bottle
Special Purpose Grease	99857-97A	14 oz cartridge
Type "E" Hydraulic Fork Oil	62600026	16 oz bottle
Wheel Bearing Grease	99855-89	1 lb can
	99856-92	14 oz cartridge

* Not a Harley-Davidson part number

See this article in russian language

Article about repair motorcycles «Harley Sportster XL1200» (2012-2023): «Maintenance schedule of motorcycle»: https://motoinstruction.ru/en/Harley/Sportster/XL_2012/owner/service/112939 <a href="https://motoinstruction.ru/en/Harley/Sportster/XL_2012/owner/service/112939">Maintenance schedule of motorcycle</a> - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Maintenance». [url=https://motoinstruction.ru/en/Harley/Sportster/XL_2012/owner/service/112939]Maintenance schedule of motorcycle[/url] - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Maintenance».