Positioning:
The Harley-Davidson Sportster line, particularly the XLH1200, represented a cornerstone of the brand's offerings in the late 1990s, appealing to riders seeking classic V-twin performance and customization potential.
Competitors:
Competed against other American V-twin cruisers and performance motorcycles, as well as some European and Japanese offerings in the cruiser segment.
Features Of Xlh1200 1998:
Evolution V-twin engine, iconic Sportster styling, robust frame, emphasis on rider engagement and sound.
Value For Buyers:
Essential for owners and independent mechanics to perform accurate maintenance, repairs, and troubleshooting, ensuring the longevity and optimal performance of a classic Harley-Davidson.
Vehicle Coverage:
All Harley-Davidson Sportster XLH1200 models for the 1998 model year.
Manual Sections:
Covers engine, transmission, chassis, suspension, brakes, electrical, fuel system, bodywork, and more.
Estimated Pages:
Est. 500+ pages (typical for this era's comprehensive manuals)
Type:
Workshop Repair Service Manual
Engine:
Disassembly, assembly, tuning, lubrication, cooling system (air-cooled), internal components, performance tuning.
Transmission:
Gearbox disassembly, assembly, lubrication, clutch operation, shifter mechanism, final drive.
Electrical System:
Wiring diagrams, lighting, ignition system, starter motor, charging system (alternator/stator, regulator/rectifier), battery, fuses, relays, instrument cluster, horn.
Fuel System:
Carburetor (Keihin CV type) tuning and overhaul, fuel lines, fuel tank, fuel filter, fuel pump (if applicable).
Brakes:
Front and rear brake system maintenance, hydraulic components, caliper service, brake pad replacement, fluid bleeding, master cylinder.
Suspension:
Front fork (e.g., Showa) overhaul, fork oil replacement, rear shock absorber adjustment and replacement, swingarm and bearings.
Chassis And Frame:
Frame inspection, steering head bearings, wheel bearings, swingarm pivot.
Bodywork And Trim:
Fenders, fuel tank removal/installation, seat, handlebars, controls, fairings/covers.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems.
Disassembly Assembly:
Complete instructions for taking apart and putting back together all major vehicle systems.
Tune Up:
Carburetor tuning, ignition timing checks, engine adjustments.
Wiring Diagrams:
Detailed and accurate electrical wiring diagrams essential for diagnosing and repairing electrical issues.
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners and components.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and complex electrical diagnostics.
Diagnostic Guides:
Includes specific troubleshooting trees and diagnostic procedures for various fault conditions.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.7 cu. in.)
Bore X Stroke:
3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)
Compression Ratio:
8.8:1 (typical for this generation)
Horsepower:
Approx. 60-65 HP (at crank)
Torque:
Approx. 68-72 ft-lbs (at crank)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended.
Ignition Type:
Electronic ignition (breakerless)
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 34/46 tooth (1.35:1 ratio)
Final Drive:
Belt drive, 32/65 tooth (2.03:1 ratio)
Clutch:
Wet, multi-plate, diaphragm spring
Transmission Fluid Type:
Harley-Davidson Formula + or equivalent Syn3 (check manual for specific recommendations), typically SAE 50 or SAE 20W-50 motorcycle oil.
Transmission Fluid Capacity:
Approx. 2.5 US quarts (2.4 Liters)
Length:
Approx. 88.8 inches (2255 mm)
Width:
Approx. 32.7 inches (830 mm)
Height:
Approx. 48.5 inches (1232 mm)
Dry Weight:
Approx. 500 lbs (227 kg)
Gross Vehicle Weight Rating:
Approx. 930 lbs (422 kg)
Wheelbase:
Approx. 60.0 inches (1524 mm)
Ground Clearance:
Approx. 4.5 inches (114 mm)
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first) - typically includes oil change, filter change, primary chain adjustment, and general inspection.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for regular maintenance, including oil changes, lubrication, and inspections. Specific intervals for spark plugs, brake fluid, fork oil vary.
Engine Oil Type:
Harley-Davidson recommends SAE 20W-50 motorcycle oil (synthetic or conventional). Formula+ or Syn3 can be used for engine, transmission, and primary drive.
Engine Oil Capacity:
Approx. 3 US quarts (2.8 Liters) with filter change.
Brake Fluid Type:
DOT 4 recommended for hydraulic brake systems.
Fork Oil Type:
Specific weight (e.g., 10W or 15W) and quantity per fork leg as per manual, typically a good quality fork oil.
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, battery. Carburetor adjustments may be needed over time.
Potential Issues:
Aging electrical connectors, cam chain tensioner wear (especially in earlier Evolution models, though less critical on later ones), rear belt guard stress cracks.
Brand Legacy:
Harley-Davidson boasts a long and storied history dating back to 1903, synonymous with American motorcycling culture and V-twin engine design.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model nameplate. The XLH1200 of 1998 is part of the 'Evolution' era, succeeding the Shovelhead and Ironhead engines, offering improved reliability and performance.
Manufacturing Location:
York, Pennsylvania, USA (Harley-Davidson's primary manufacturing facility).
