Harley Davidson Sportster 1200 2010 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster 1200 Year: 2010 Variant: All models Codes Oem Manual Id: 99492-10 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Harley-Davidson Sportster...

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Mots clés: 2010 Harley Davidson Misc Motorcycle Motorcycles Sportster 1200

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster 1200

Year:

Variant:

All models

Codes

Oem Manual Id:

99492-10

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson Sportster 1200 owners, independent repair shops, mechanics

Competitive Analysis

Key Competitors:

Indian Scout, Triumph Bonneville, Yamaha Bolt

Key Features

Vehicle Identity:

Iconic American V-twin cruiser, known for its classic styling and accessible performance

Manual Value:

Provides the definitive guide for maintaining and repairing the 2010 Sportster 1200, empowering owners and technicians

📋 Manual Details

Coverage Areas

Engine Service:

Complete

Transmission Service:

Complete

Electrical System:

Complete

Chassis And Suspension:

Complete

Fuel System:

Complete

Brake System:

Complete

Body And Frame:

Complete

Troubleshooting:

Comprehensive

Page Count

Estimated Pages:

Hundreds (exact count not specified in product info, typical for Harley factory manuals)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

1200cc Evolution V-Twin engine (carbureted and fuel-injected variants as applicable to 2010 Sportster 1200 models)

Transmission:

5-speed Cruise Drive transmission

Clutch:

Clutch operation, adjustment, and component service

Fuel Delivery:

Fuel tank, fuel lines, fuel pump, fuel injectors (EFI models), carburetor (carbureted models), throttle body

Ignition System:

Ignition module, spark plugs, ignition coils, crank position sensors

Exhaust System:

Exhaust pipes, mufflers, catalytic converter (if applicable)

Cooling System:

Air-cooled engine, oil cooling system (if equipped)

Lubrication System:

Oil pump, oil filter, oil lines, oil capacity, oil change procedures

Electrical System:

Battery, charging system (stator, voltage regulator), starting system (starter motor, solenoid), lighting, instrumentation, horn, wiring diagrams

Lighting:

Headlight, taillight, turn signals, brake lights, dashboard illumination

Instrumentation:

Speedometer, tachometer, indicator lights, diagnostic codes

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, rotors, brake fluid specifications

Suspension:

Front forks (cartridge type), rear shock absorbers, fork oil specifications, rear suspension adjustments

Wheels And Tires:

Wheel types, tire sizes, tire pressure specifications, wheel bearing service

Frame And Bodywork:

Frame construction, body panels, fenders, fuel tank mounting, seat mounting

Steering:

Handlebars, triple clamps, steering head bearings, adjustment and service

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication/adjustment (if applicable to model), tire pressure checks, brake fluid checks, spark plug replacement

Engine Overhaul:

Piston removal/installation, cylinder head service, valve adjustments, camshaft replacement, crankshaft service

Transmission Service:

Clutch plate replacement, gear inspection, bearing service, transmission fluid changes

Electrical Diagnostics:

Troubleshooting electrical faults, wiring harness inspection, component testing

Fuel System Repair:

Carburetor cleaning and adjustment, fuel injector cleaning, fuel pump replacement, throttle cable adjustment

Brake System Maintenance:

Brake pad replacement, caliper service, bleeding the brake system, master cylinder overhaul

Suspension Service:

Fork seal replacement, fork oil change, rear shock absorber replacement or service

Wheel And Tire Service:

Tire mounting and balancing, wheel bearing replacement

Troubleshooting Guides:

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

Torque Specifications:

Detailed torque values for all critical fasteners

Technical Depth

Depth:

Comprehensive factory-level repair and diagnostics

Diagnostics:

Detailed diagnostic flowcharts and trouble codes (DTCs) for EFI models

Rebuilds:

Engine and transmission rebuild procedures included

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable, facilitating quick information retrieval

Print Quality

Quality:

High-resolution, suitable for clear printing of text and diagrams

Binding Type

Binding:

N/A (Downloadable PDF; intended for digital use or user-printed binding)

Paper Type

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Evolution V-Twin, Air-Cooled

Displacement:

1200cc (73.2 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.0:1 (typical for this era)

Valvetrain:

Pushrod-actuated overhead valves, 2 valves per cylinder

Performance

Horsepower:

Approximately 60-67 HP (exact figures vary slightly by year and tuning, typical range)

Torque:

Approximately 70-75 ft-lbs @ 3500-4000 RPM (typical range)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV 40mm Carburetor (depending on specific 1200 model variant for 2010)

Fuel Type:

Unleaded gasoline, minimum 91 octane (95 RON) recommended

Lubrication System

Oil Type:

Harley-Davidson Genuine V-Twin Oil 20W-50 or equivalent API SG, or higher, JASO FD, FD2, or FL approved motorcycle oil

Oil Capacity:

Approx. 3 quarts (2.8 liters) with filter change

🔧 Transmission

Standard

Type:

5-speed Cruise Drive

Gear Ratios:

1st: 10.335, 2nd: 7.242, 3rd: 4.946, 4th: 3.929, 5th: 3.216 (Typical values, confirm with manual)

Features

Clutch:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson Syn3 or equivalent SAE 75W-90 GL-5 gear oil

Transmission Oil Capacity:

Approx. 2.7 quarts (2.55 liters)

📐 Dimensions

Exterior

Wheelbase:

Approx. 59.6 inches (1515 mm)

Weights

Dry Weight:

Approx. 577 lbs (262 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 1000 lbs (454 kg)

🛡️ Safety Features

Ratings

Safety Certification:

DOT (Department of Transportation) compliant lighting and braking systems

Active Features

Brakes:

Dual-piston front caliper with 292mm disc, dual-piston rear caliper with 292mm disc

Passive Features

Frame Construction:

Steel frame and swingarm

💡 Technology Features

Infotainment

Audio System:

Optional accessory audio systems available; base models typically do not include integrated infotainment.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature for 2010 models, not standard on all variants.

Connectivity

Diagnostics Port:

J1850 VPM (Vehicle Protocol Module) for electronic diagnostics on EFI models.

🔧 Maintenance

Service Intervals

Initial Service:

1000 miles (1600 km) or 6 months

Subsequent Service:

Every 5000 miles (8000 km) or 12 months thereafter

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin Oil 20W-50 (API SG, JASO FD/FD2/FL approved)

Transmission Oil:

Harley-Davidson Syn3 or SAE 75W-90 GL-5 gear oil

Brake Fluid:

DOT 4

Fork Oil:

Harley-Davidson Type E (5W) or Type H (10W) fork oil (specific weight depends on rider preference and model variant)

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, spark plugs

Potential Electrical Issues:

Voltage regulator failure, stator issues (less common on later models but still possible), loose electrical connections

Fuel System Maintenance:

Carburetor cleaning for older models, occasional injector cleaning for EFI models

📚 Vehicle History

Brand Heritage

Brand Origin:

Founded in Milwaukee, Wisconsin, USA, in 1903

Model Evolution

Sportster Lineage:

The Sportster line has been in continuous production since 1957, evolving significantly over the decades while retaining its core identity.

2010 Updates:

The 2010 models continued the evolution of the Sportster platform, featuring fuel injection as standard on most variants, along with other refinements in styling and components.

Production

Manufacturing Location:

United States (Milwaukee, Wisconsin or Kansas City, Missouri)

🏆 Awards & Recognition

Recognitions

Sportster Legacy:

The Sportster line is consistently recognized for its enduring appeal and ability to be customized, often cited in 'best cruiser' lists.