🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster 1200

Year:

2010

Model Line:

Sportster

Engine Variant:

1200cc Evolution Engine

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking classic styling with modern performance, often customization-oriented enthusiasts.

Competitors 2010:

Other V-twin cruisers from brands like Indian, Triumph (Bonneville), and some Japanese manufacturers offering similar displacement/style.

Styling:

Iconic Harley-Davidson styling, classic American cruiser aesthetic.

Engine Platform:

Proven and reliable Evolution V-twin engine.

Customization Potential:

Highly customizable platform, a hallmark of the Sportster line.

Value Proposition:

Empowers owners and technicians with the knowledge to maintain, repair, and optimize their Sportster 1200.

📋 Manual Details

Coverage Summary:

Comprehensive repair and overhaul for Harley-Davidson Sportster 1200 2010 models.

Diagnostic Coverage:

Includes troubleshooting guides and diagnostic procedures for all major systems.

Estimated Page Count:

Approximately 500-700 pages (typical for a full service manual of this era).

Manual Type:

Service / Workshop Repair Manual

Language:

English

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, inspection, and repair procedures for the Evolution 1200cc V-Twin engine.

Fuel System:

Carburetor (if applicable for specific markets/sub-models) or Electronic Fuel Injection (EFI) system diagnosis, service, and calibration.

Ignition System:

Ignition module, coil, spark plugs, and timing adjustments.

Transmission:

5-speed constant mesh transmission service, clutch operation, and related components.

Drivetrain:

Primary drive, clutch, transmission, and final belt drive system maintenance and repair.

Chassis And Frame:

Frame inspection, steering head bearing service, and suspension component maintenance.

Front Suspension:

Fork disassembly, seal replacement, fluid levels, and damper rod adjustments.

Rear Suspension:

Shock absorber service, adjustment, and mounting.

Brakes:

Front and rear brake system service, including caliper overhaul, pad replacement, fluid flush, and ABS (if equipped) troubleshooting.

Electrical System:

Wiring diagrams, battery service, charging system (stator, regulator/rectifier), starter motor, lighting, and accessory circuits.

Instrumentation And Controls:

Speedometer, tachometer, indicator lights, and control switchgear service.

Bodywork And Trim:

Fender removal/installation, fuel tank maintenance, seat service, and exterior trim.

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure, and wheel balancing.

Exhaust System:

Exhaust pipe and muffler removal, installation, and gasket replacement.

Diagnostics:

Troubleshooting specific symptoms, fault codes (if applicable), and diagnostic flowcharts.

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, and general inspection procedures.

Component Rebuilds:

Detailed step-by-step instructions for rebuilding key components like the engine, transmission, and brake calipers.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common and uncommon mechanical and electrical issues.

Electrical Troubleshooting:

Using wiring diagrams to trace circuits and identify faults in the electrical system.

Torque Specifications:

Precise torque values for all critical fasteners and bolts.

Special Tools:

Identification of required Harley-Davidson specific and aftermarket tools for various procedures.

Wiring Diagrams:

Comprehensive, easy-to-read electrical wiring schematics for the entire motorcycle.

Depth:

Suitable for professional technicians and experienced DIY mechanics. Covers from basic maintenance to complete engine and transmission overhauls.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Typically yes, for ease of finding specific information.

Image Clarity:

High resolution images, diagrams, and illustrations.

Binding Type For Physical:

N/A (Digital PDF)

Paper Type For Physical:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution, 45-degree V-twin

Displacement:

1203 cc (73.4 cubic inches)

Bore X Stroke:

3.56 in. x 3.81 in. (90.4 mm x 96.8 mm)

Compression Ratio:

9.0:1 (typical for this era Sportster)

Valve Train:

Overhead valves (OHV) with pushrods, 2 valves per cylinder

Horsepower Est:

Approximately 65-70 hp at 5000-5500 rpm (market dependent)

Torque Est:

Approximately 70-75 ft-lbs at 3500-4000 rpm (market dependent)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) or Carburetor (depending on market/specific model variant)

Fuel Type:

Unleaded gasoline, minimum 91 octane (R+M)/2

Oil Capacity:

Approximately 3.0 quarts (2.8 liters) with filter change.

Oil Type:

Harley-Davidson SYN3 Synthetic Motorcycle Oil or equivalent SAE 20W-50 premium synthetic engine oil.

🔧 Transmission

Transmission Type:

5-speed, constant mesh

Primary Drive:

Clutch, #40 Duplex chain

Final Drive:

Belt drive, 25mm, 140-tooth (rear), 32-tooth (front sprocket)

Clutch:

Clutch: Wet, multi-plate, diaphragm spring

Transmission Fluid:

Harley-Davidson Transmission & Primary Chaincase Lubricant or equivalent SAE 85W-140.

📐 Dimensions

Length:

Approx. 88.4 in. (2245 mm)

Width:

Approx. 31.5 in. (800 mm)

Height:

Approx. 48.2 in. (1224 mm)

Wheelbase:

Approx. 60.0 in. (1524 mm)

Ground Clearance:

Approx. 4.3 in. (109 mm)

Dry Weight:

Approx. 550 lbs (250 kg)

Gvwr:

Approx. 930 lbs (422 kg)

Payload Capacity:

Approx. 380 lbs (172 kg)

Fuel Capacity:

4.5 gallons (17 liters)

🛡️ Safety Features

Safety Certification:

Certified for road use in target markets (e.g., DOT, EPA compliant).

Braking System:

Hydraulic disc brakes front and rear. Optional ABS may be present on certain trims.

Lighting:

Halogen headlamp, LED tail lamp, incandescent turn signals.

Frame Construction:

Steel frame and swingarm for robust construction.

💡 Technology Features

Instrument Cluster:

Analog speedometer, LCD odometer, trip meter, clock, and indicator lights. Tachometer is often integrated or an optional add-on.

ABS:

Anti-lock Braking System (ABS) was an available option on some 2010 Sportster models.

Diagnostic Port:

Proprietary Harley-Davidson diagnostic port for reading fault codes and system data.

🔧 Maintenance

First Service:

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

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months thereafter. (Refer to manual for exact intervals for specific items).

Engine Oil Viscosity:

SAE 20W-50 Premium Synthetic Motorcycle Oil.

Transmission Fluid Viscosity:

SAE 85W-140 Harley-Davidson Transmission & Primary Chaincase Lubricant.

Brake Fluid Type:

DOT 4, High-Temperature Brake Fluid.

Fork Oil Type:

Harley-Davidson Type 'E' (or equivalent SAE 10W) Fork Oil.

Common Wear Items:

Clutch plates, wheel bearings, brake pads, drive belt, fork seals.

Engine Specific Considerations:

Regular oil changes are critical for longevity due to shared primary/transmission oil in some configurations (though Sportster generally has separate primary/transmission).

Electrical Common Points:

Battery terminals, grounds, and charging system components (regulator/rectifier) can be prone to corrosion or failure over time.

Spark Plugs:

Replace every 10,000-15,000 miles (16,000-24,000 km) or as needed. Recommended: NGK DCPR7E.

Air Filter:

Inspect every 5,000 miles (8,000 km), clean or replace as needed. Specific part number varies by air cleaner assembly.

Belt Tension Adjustment:

Check and adjust belt tension every 5,000 miles (8,000 km) or as per manual specification.

📚 Vehicle History

Brand Origin:

Founded in Milwaukee, Wisconsin, USA, in 1903. One of the oldest motorcycle manufacturers.

Sportster Line Introduction:

The Sportster line dates back to 1957, known for its sportier feel compared to other Harley-Davidson models.

Sportster 1200 Evolution Engine:

The Evolution engine, introduced in 1984, significantly updated the Sportster line with lighter weight and improved performance. The 1200cc variant has been a staple.

2010 Model Year Updates:

The 2010 Sportster models continued the evolutionary path of the platform, with refinements to fueling, suspension, and styling. Key for this year was the continued focus on electronic fuel injection for emissions compliance and performance across global markets.

Manufacturing Location:

United States (Various Harley-Davidson facilities)

🏆 Awards & Recognition

Segment Awards:

While specific awards for the 2010 model are difficult to pinpoint, the Sportster line has consistently been recognized for its iconic design, customization potential, and enduring appeal within the cruiser market.