Harley Davidson Sportster 1200 Custom 2013 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster 1200 Custom Year: 2013 Product Type: Service Repair Manual 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Harley-Davidson Sportster 1200 Custom...

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标签: 2013 Harley Davidson Misc Motorcycle Motorcycles Sportster 1200 Custom

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster 1200 Custom

Year:

Product Type:

Service Repair Manual

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson Sportster 1200 Custom owners and independent repair shops

Competitive Analysis

Comparable Models 2013:

Indian Chief Vintage, Victory Boardwalk, Triumph Bonneville, Honda Shadow Spirit 750

Key Features

Vehicle Focus:

Customizable cruiser styling, classic V-twin performance

Manual Value Proposition:

Empowers owners with the knowledge to perform maintenance and repairs, saving time and money compared to dealership service.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical Repair and Maintenance

Diagnostic Coverage:

Troubleshooting and Diagnostics

Electrical Coverage:

Wiring Diagrams and Electrical System Repair

Page Count

Estimated Pages:

Estimated 400-600 pages (typical for this model's comprehensive service manual)

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete Engine Overhaul, Tuning, and Component Repair (e.g., cylinders, pistons, crankshaft, camshafts, valves)

Fuel System:

Fuel Injection System (EFI), Fuel Pump, Injectors, Fuel Tank, Lines, and Filters

Ignition System:

Ignition Coils, Spark Plugs, Crankshaft Position Sensor, ECU

Transmission:

Clutch Assembly, Gearbox, Shifting Mechanism, Lubrication, and Repair

Drivetrain:

Belt Drive System, Pulleys, and Bearings

Brakes:

Hydraulic Brake System, Calipers, Rotors, Master Cylinders, Hoses, Bleeding Procedures

Suspension:

Front Forks (including internal components and fluid changes), Rear Shock Absorbers, Swingarm, and Bearings

Electrical System:

Battery, Charging System (Stator, Regulator/Rectifier), Lighting System, Ignition Switch, Fuses, Relays, Horn, Starter Motor

Chassis And Frame:

Frame Inspection, Headstock Bearings, Wheel Bearings

Bodywork And Trim:

Fender Removal/Installation, Fuel Tank Removal/Installation, Seat, Handlebars, Controls

Diagnostics:

Diagnostic Trouble Codes (DTCs) and Troubleshooting Procedures

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Chain/Belt Adjustments, Spark Plug Service, Tire Pressure Checks

Major Repairs:

Engine Rebuilds, Transmission Overhauls, Suspension Overhauls, Brake System Repairs

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon issues

Electrical Diagnostics:

Testing and repair of electrical circuits and components

Wiring Diagrams:

Detailed, color-coded wiring schematics for all electrical systems

Specifications:

Torque specifications for all fasteners, fluid capacities, tolerances

Alignment Procedures:

Wheel alignment, handlebar alignment

Disassembly Assembly:

Detailed steps for dismantling and reassembling all major components

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds)

Diagnostic Level:

Advanced diagnostic procedures, including symptom-based troubleshooting

Rebuild Scope:

Complete engine, transmission, and suspension component rebuilds

📊 Manual Specifications

File Format

Format:

Searchability:

Text-searchable PDF for easy navigation

Printability:

Printable pages, allowing for hard copy reference

Print Quality

Quality:

High-resolution, clear text and diagrams

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Evolution (Sportster)

Engine Type:

Air-cooled, 45-degree V-twin

Displacement:

1200 cc (73.4 cu in)

Bore X Stroke:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valve Train:

Overhead valves (OHV), pushrod actuated, two valves per cylinder

Performance

Horsepower Estimated:

Approximately 65-70 HP (at crank)

Torque Estimated:

Approximately 71-75 lb-ft (at crank)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane

Lubrication System

Oil Type:

Harley-Davidson SYN3 (or equivalent V-Twin specific synthetic oil) meeting Harley-Davidson specification

Oil Capacity W Filter:

3.0 US qt (2.8 L)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Features

Primary Drive:

Exposed chain, 34/48 ratio

Final Drive:

Belt, 32/68 ratio

Fluid Type

Transmission Oil:

Harley-Davidson Formula + (or equivalent SAE 80W-90 gear oil meeting Harley-Davidson specification)

Fluid Capacity

Transmission Oil Capacity:

Approximately 2.7 US qt (2.5 L)

📐 Dimensions

Exterior

Length:

90.5 in (2299 mm)

Width Handlebars:

36.4 in (925 mm)

Height Seat Laden:

26.1 in (663 mm)

Ground Clearance:

4.4 in (112 mm)

Weights

Dry Weight:

570 lb (258.5 kg)

Gross Vehicle Weight Rating Gvwr:

950 lb (431 kg)

Payload Capacity:

380 lb (172 kg)

Fuel Capacity:

4.5 US gal (17.0 L)

Oil Capacity:

3.0 US qt (2.8 L)

🛡️ Safety Features

Ratings

Safety Certification:

Meets DOT and EPA requirements for its class

Active Features

Brakes:

Dual-piston front caliper with 300mm floating rotor, dual-piston rear caliper with 260mm floating rotor

Tires:

Tubeless tires

Passive Features

Lighting:

Halogen headlight, LED tail light, incandescent turn signals

💡 Technology Features

Infotainment

Audio System:

Optional factory-installed audio system available on some trims, typically AM/FM radio and CD player.

Display:

Analog speedometer with integrated LCD display for odometer, trip meter, gear indicator (if equipped).

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature for the 2013 Sportster 1200 Custom.

Connectivity

Connectivity Features:

Limited to basic wired connections for optional audio accessories.

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 6 months

Subsequent Services:

Every 5,000 miles (8,000 km) or 12 months (whichever comes first)

Engine Oil Change:

Every 5,000 miles (8,000 km) or 12 months

Transmission Oil Change:

Every 10,000 miles (16,000 km) or 24 months

Primary Chain Tensioner:

Inspect at 1,000 miles, then every 5,000 miles. Replace with improved hydraulic tensioner if applicable.

Fluid Specifications

Engine Oil:

Harley-Davidson SYN3 (SAE 20W-50) or equivalent meeting Harley-Davidson spec

Transmission Oil:

Harley-Davidson Formula + (SAE 80W-90) or equivalent

Primary Chain Case Oil:

Harley-Davidson Formula + (SAE 80W-90) or equivalent

Brake Fluid:

DOT 4

Known Issues

Primary Chain Tensioner Wear:

Early models (prior to hydraulic tensioner upgrade) are prone to tensioner shoe wear, which can lead to noise and potential chain damage. The manual will cover inspection and replacement.

Wiring Harness Chafing:

Potential for wiring harnesses to chafe against frame components. Manual will detail inspection points.

Idle Control Module Issues:

Occasional issues with idle stability or stalling due to the Idle Air Control (IAC) system or related sensors.

📚 Vehicle History

Brand Heritage

Brand Origin:

Founded in Milwaukee, Wisconsin, USA, 1903

Legacy:

Iconic American motorcycle manufacturer known for its V-twin engines and cruiser styling.

Model Evolution

Sportster Lineage:

The Sportster line dates back to 1957, evolving from the K-model. It's Harley-Davidson's longest continuously produced motorcycle model.

2013 Updates:

While the 1200 Custom retained its classic styling, 2013 models featured an evolution of the fuel injection system and potentially minor electrical or cosmetic refinements.

Production

Manufacturing Location:

United States

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The Sportster line consistently receives positive reviews for its character, customization potential, and V-twin rumble.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for reliability and the riding experience, particularly among riders who value classic styling and customization.

Certifications

Emissions:

Meets EPA emissions standards for the model year.