Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Sportster owners, independent repair shops, enthusiasts seeking in-depth maintenance and repair knowledge.
Manual Value Proposition:
Offers significantly more detail and practical guidance than a standard owner's manual, enabling owners to perform a wide range of tasks themselves, saving on labor costs.
Completeness:
Covers all major systems and common repair procedures for the specific model and year.
Instruction Style:
Step-by-step instructions with clear diagrams and illustrations.
Primary Coverage:
Service, Maintenance, and Repair
Specific Systems Covered:
Engine, Drivetrain, Chassis, Electrical, Fuel System, Brakes, Suspension, Controls, Bodywork, Diagnostics
Estimated Pages:
Approx. 500-700 (typical for comprehensive service manuals of this era)
Type:
Service Manual (Shop Manual)
Format:
Print (Paperback/Bound)
Engine:
Complete engine overhaul, component disassembly/assembly, lubrication, cooling system (air-cooled), internal component specifications
Drivetrain:
Clutch operation and adjustment, primary drive, transmission disassembly and assembly, final drive (belt drive) inspection and maintenance
Chassis:
Frame inspection, steering head bearing adjustment, wheel bearing service, suspension fork disassembly and rebuilding, shock absorber service and replacement, brake system (hydraulic front, rear drum/disc variations possible) overhaul and bleeding
Electrical:
Wiring diagrams, ignition system troubleshooting and repair, lighting circuits, battery maintenance, starter motor and charging system testing, accessory wiring
Fuel System:
Carburetor (likely Keihin CV) disassembly, cleaning, and adjustment; fuel tank and lines inspection; fuel pump (if applicable) testing
Maintenance:
Routine servicing, oil changes, filter replacements, chain/belt adjustment, spark plug replacement, brake pad replacement, lubrication points
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly for all major systems
Diagnostics:
Torque specifications, electrical resistance values, timing adjustments, general diagnostic procedures
Depth:
Comprehensive, covering basic owner maintenance to advanced internal engine and transmission rebuilds, with detailed technical specifications and diagnostic information.
File Format:
N/A (Print Manual)
Print Quality:
High-quality paper stock with clear text and diagrams, suitable for workshop environment.
Binding Type:
Professional binding (e.g., saddle-stitched, perfect bound, or spiral-bound for workshop use).
Paper Type:
Durable, grease-resistant paper stock.
Engine Type:
Air-Cooled, Evolution V-Twin
Displacement:
1200cc (73.4 cubic inches)
Bore X Stroke:
3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)
Horsepower:
Approx. 67 HP @ 5500 RPM (Estimate, actual may vary slightly by tuning)
Torque:
Approx. 70 ft-lbs @ 3500 RPM (Estimate, actual may vary slightly by tuning)
Fuel Delivery:
Carbureted (Likely Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, minimum 91 octane (AKI)
Oil Type:
Harley-Davidson Genuine V-Twin Oil (or equivalent SAE 20W-50 motorcycle oil)
Oil Capacity:
3.0 US qt (2.8 L)
Ignition System:
Electronic, Spark Ignited
Transmission Type:
5-Speed Constant Mesh
Gear Ratios:
Detailed in manual, typically: 1st: 3.01, 2nd: 2.17, 3rd: 1.60, 4th: 1.23, 5th: 1.00
Primary Drive:
1.36:1, Chain
Final Drive:
2.75:1, Belt Drive
Transmission Fluid Type:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent SAE 50 motorcycle lubricant)
Transmission Fluid Capacity:
1.0 US qt (0.95 L)
Length:
Approx. 90.5 in. (2299 mm)
Width:
Approx. 32.3 in. (820 mm)
Height:
Approx. 46.1 in. (1171 mm)
Seat Height:
Approx. 26.5 in. (673 mm) (Unladen)
Dry Weight:
Approx. 578 lbs (262 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 965 lbs (438 kg)
Fuel Capacity:
4.5 US gal (17 L)
Safety Ratings:
Motorcycles are not rated by NHTSA/IIHS for crash safety in the same manner as cars. Safety is dependent on rider skill and adherence to maintenance.
Braking System:
Hydraulic front disc brake, Rear disc brake (or drum, depending on specific sub-model configurations and regional variations). Dual-piston front caliper.
Lighting:
Halogen headlamp, LED taillight, incandescent turn signals.
Frame Construction:
Steel, cradle frame.
Infotainment System:
Typically none on this model, focusing on core motorcycle functionality. Some aftermarket audio systems may be available.
Driver Assistance Features:
N/A. This model does not feature electronic rider aids like ABS or traction control as standard.
Connectivity Features:
N/A. Focus is on mechanical and basic electrical systems.
First Service:
1000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5000 miles (8000 km) or 12 months, whichever comes first.
Oil Change Interval:
Every 5000 miles (8000 km) or 12 months. (Check manual for specific guidance)
Engine Oil:
Harley-Davidson Genuine V-Twin Oil SAE 20W-50 or approved equivalent.
Transmission Primary Fluid:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant or approved equivalent SAE 50.
Brake Fluid:
DOT 4 (for hydraulic systems)
Carburetor Tuning:
CV carburetor can require periodic tuning and adjustment for optimal performance, especially with modifications.
Belt Tension:
Drive belt tension requires regular checking and adjustment to prevent premature wear.
Electrical Connections:
Corrosion or loosening of electrical connectors can lead to intermittent issues.
Rear Shock ABSorbers:
Stock rear shocks may offer limited damping for aggressive riding or heavier loads; aftermarket upgrades are common.
Brand Origin:
Founded in Milwaukee, Wisconsin, USA, in 1903.
Sportster Lineage:
The Sportster line is one of Harley-Davidson's longest continuously produced motorcycle models, with its origins dating back to the 1950s.
Evolution Engine:
The Evolution V-Twin engine, introduced in the 1980s, has been a staple for Harley-Davidson motorcycles, including the Sportster series.
Xl 1200L Introduction:
The 'Low' variant (XL designation) was introduced to cater to riders seeking a more accessible seat height and comfortable riding position.
Manufacturing Location:
United States
