Segment:
Performance Cruiser / Sportbike Variant
Target Audience:
Enthusiast owners seeking to perform their own maintenance and repairs
Competitors 1998:
Yamaha Virago, Honda Shadow, Kawasaki Vulcan
Xlh1200S Distinction:
Higher performance focus with upgraded suspension and larger carburetors compared to standard Sportsters
Xlh1200S Sport:
Dual front disc brakes, adjustable suspension, larger engine displacement for the Sportster line
Engine:
Complete overhaul, tuning, carburetor, ignition, lubrication, cooling
Transmission:
Disassembly, assembly, clutch, gearbox, drive belt inspection
Electrical System:
Wiring diagrams, battery, charging system, lighting, ignition system, starter
Chassis And Suspension:
Frame, forks, shocks, swingarm, steering head bearings
Braking System:
Front and rear brake calipers, master cylinders, hydraulic lines, pads, rotors
Fuel System:
Fuel tank, fuel lines, fuel filter, fuel pump (if applicable), carburetor (Keihin CV)
Exhaust System:
Mufflers, headpipes, heat shields, mounting hardware
Bodywork And Trim:
Fenders, tank, seat, handlebars, controls, fairings (if applicable)
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, brake fluid flush
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common issues
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Component Rebuild:
Detailed guides for rebuilding engines, transmissions, carburetors, and brake systems
Wiring Diagrams:
Comprehensive electrical schematics for all components
Specifications And Tolerances:
Torque specifications, clearances, wear limits for all adjustable components
Depth:
Comprehensive (from basic maintenance to full engine rebuilds)
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.4 cubic inches)
Bore X Stroke:
3.496 in x 3.812 in (88.8 mm x 96.8 mm)
Valve Train:
OHV, 2 valves per cylinder, pushrod activated
Ignition System:
Electronic, single fire
Horsepower Est:
Approx. 65-70 HP (at crankshaft, estimates vary)
Torque Est:
Approx. 68-72 ft-lbs (at crankshaft, estimates vary)
Carburetor:
Keihin CV 40mm
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Capacity:
3.5 gallons (13.2 liters)
Length:
Approx. 89.2 inches (2266 mm)
Width Handlebar:
Approx. 35 inches (889 mm)
Height:
Approx. 48.5 inches (1232 mm)
Dry Weight:
Approx. 485 lbs (220 kg)
Gross Vehicle Weight Rating:
Approx. 960 lbs (435 kg)
Wheelbase:
60.2 inches (1529 mm)
Front Tire Size:
MT90B16 72H
Rear Tire Size:
130/90B16 67H
Wheel Type:
Cast aluminum
Wheel Bolt Pattern:
N/A (Hub mount, not bolt pattern)
Safety Certifications:
Meets all applicable federal motor vehicle safety standards for motorcycles
Brakes:
Dual front hydraulic disc brakes, single rear hydraulic disc brake
Suspension:
Adjustable front forks (preload), adjustable rear shock absorbers (preload and rebound)
Lighting:
Halogen headlamp, tail lamp, brake light, front and rear turn signals
Oil Change Interval:
Every 2,500 - 5,000 miles or 6 months, whichever comes first (refer to manual for exact schedule)
Primary Chain Tensioner Inspection:
Inspect at 1,000 mile intervals and adjust as needed. Automatic tensioner update may be present on later models.
Spark Plug Replacement:
Every 5,000 - 10,000 miles
Drive Belt Inspection:
Check tension and condition at every service
Engine Oil Type:
Harley-Davidson 20W50 Motorcycle Oil (or equivalent API SG/SH/SJ rated oil)
Engine Oil Capacity:
2.8 US quarts (2.6 L) with filter change
Brake Fluid Type:
DOT 4 Hydraulic Fluid
Primary Chain Case Oil Type:
Harley-Davidson Primary Chain Lubricant or Formula+ (or equivalent)
Primary Chain Case Oil Capacity:
3.2 US quarts (3.0 L) - Check level via inspection plug
Primary Chain Tensioner:
Early models (pre-2000) often had a spring-loaded primary chain tensioner prone to premature wear. Manual details inspection and replacement.
Carburetor Tuning:
Keihin CV carburetor can require periodic adjustment for optimal performance and fuel economy. Manual covers tuning procedures.
Rear Shock Leaks:
Older shock absorbers can develop leaks. Manual provides replacement and adjustment guidance.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues. Manual provides diagnostic steps.
Heritage:
Harley-Davidson's rich history dating back to 1903, known for V-twin engines and cruiser motorcycles.
Sportster Lineage:
The Sportster line began in 1957 and has evolved significantly, with the 1200cc engine becoming a performance staple.
Xlh1200S Introduction:
The 'S' designation in the early 1990s signified enhanced performance, often including upgraded suspension and braking components.
Production Period:
1998 model year
Manufacturing Location:
York, Pennsylvania, USA
Sportster 1200S Recognition:
The XLH1200S was recognized by enthusiasts for its improved handling and braking over standard Sportster models of its era, often praised for its sportier riding experience.
Performance Rating:
Considered a strong performer within the cruiser segment for its year.
Manual Certification:
This manual is compiled from official Harley-Davidson service information and industry best practices.
