Harley Davidson Sportster 1200 Roadster 2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster 1200 Roadster Year: 2007 Codes Engine Family: Evolution Vin Code: 1HD1CY... 👋 Introduction Market Position Segment: Cruiser/Sportbike hybrid motorcycle Target Audience: Enthusiasts...

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Type: Motorcycle

Vendor:

Sku: 483790

Tags: 2007 Harley Davidson Misc Motorcycle Motorcycles Sportster 1200 Roadster

Product variants

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster 1200 Roadster

Year:

Codes

Engine Family:

Evolution

Vin Code:

1HD1CY...

👋 Introduction

Market Position

Segment:

Cruiser/Sportbike hybrid motorcycle

Target Audience:

Enthusiasts seeking a blend of classic Harley-Davidson style with sportier handling and performance

Competitive Analysis

Competitors:

Other mid-weight cruisers and roadsters from brands like Triumph, Indian, and some Japanese manufacturers.

Key Features

Design Philosophy:

Sportier iteration of the iconic Sportster platform, emphasizing handling and performance over pure cruiser comfort.

Dual front disc brakes, inverted front forks, sporty ergonomics

📋 Manual Details

Coverage Areas

Engine:

Complete overhaul, troubleshooting, diagnostics

Transmission:

Removal, installation, internal repairs, clutch service

Fuel System:

Carburetor (Keihin CV) service, fuel pump, fuel lines

Electrical System:

Wiring diagrams, ignition, starting, charging, lighting, diagnostics

Suspension:

Front fork (49mm USD) overhaul, rear shock absorbers, adjustments

Brakes:

Front and rear brake caliper service, master cylinders, bleeding, pad replacement

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearing replacement

Bodywork:

Fender removal/installation, tank service, seat removal, minor body repairs

Page Count

Estimated Pages:

~400-600

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, final drive (belt)

Running Gear:

Suspension, brakes, wheels, tires, steering

Electrical:

Ignition, charging, starting, lighting, instrumentation, accessories

Chassis:

Frame, body panels, seat, fuel tank, exhaust system

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug service, chain/belt adjustment, brake fluid flush, fork oil changes

Troubleshooting:

Diagnostic procedures for common performance and electrical issues, fault codes

Repair:

Engine internal component replacement, transmission rebuild, brake system overhauls, suspension fork rebuilds, electrical component repair

Diagnostics:

Step-by-step diagnostic flowcharts, testing procedures for electrical components and sensors

Technical Depth

Level:

Comprehensive: From routine maintenance to complete engine and transmission rebuilds

📊 Manual Specifications

File Format

Quality:

High-resolution, clear text and diagrams

Searchable:

Yes, fully text-searchable

Print Quality

Printability:

Printable

Binding Type

Binding:

N/A (PDF Format)

Paper Type

Paper:

N/A (PDF Format)

⚙️ Engine Specifications

Primary Engine

Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.7:1

Valvetrain:

OHV, 2 valves per cylinder

Ignition System:

Electronic, Spark Ignition

Performance

Horsepower:

~65-70 hp (estimated, at crankshaft)

Torque:

~70-75 lb-ft (estimated, at crankshaft)

Fuel System

Type:

Mikuni HSR42 Carburetor (Keihin CV40 on earlier models, but 2007 is typically Mikuni for Roadster)

Fuel Type:

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

🔧 Transmission

Standard

Type:

5-speed Manual

Primary Drive:

Constant mesh, helical gears, chain drive to clutch

Clutch:

Clutch type: Wet, multi-plate, diaphragm spring

Final Drive:

Belt drive

Features

Gear Ratios:

1st: 10.373, 2nd: 7.245, 3rd: 5.040, 4th: 3.906, 5th: 3.105

Transmission Oil Type:

Harley-Davidson recommends Harley-Davidson Transmission Lubricant or SAE 80W-90 hypoid gear oil

📐 Dimensions

Exterior

Length:

~88.3 in (2243 mm)

Width:

~32.3 in (820 mm)

Height:

~45.7 in (1161 mm)

Wheelbase:

~60.0 in (1524 mm)

Weights

Dry Weight:

~536 lbs (243 kg)

Gross Vehicle Weight Rating:

~937 lbs (425 kg)

Cargo

Fuel Capacity:

4.5 US gallons (17 liters)

🛡️ Safety Features

Ratings

Crash Test Data:

Not applicable (motorcycle)

Active Features

Braking System:

Dual front hydraulic disc brakes, single rear hydraulic disc brake

Lighting:

Halogen headlight, LED tail light and brake light

Passive Features

Frame Construction:

Steel frame and swingarm

Ergonomics:

Forward-mounted foot controls, raised handlebars for a sportier rider triangle

💡 Technology Features

Infotainment

Display:

Analog speedometer with integrated digital odometer and tachometer (depending on exact configuration).

Audio System:

None standard

Driver Assistance

Not standard on this model

Connectivity

Usb Ports:

None standard

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 miles or 6 months, whichever comes first

Primary Chain Tension Check:

Every 10,000 miles

Belt Tension Check:

Every 10,000 miles

Spark Plug Replacement:

Every 10,000 miles

Brake Fluid Flush:

Every 2 years

Fork Oil Change:

Every 20,000 miles or as needed

Fluid Specifications

Engine Oil Capacity:

3.0 US quarts (2.8 liters) with filter change

Engine Oil Type:

Harley-Davidson 20W-50 Syn3 or equivalent motorcycle-specific 20W-50 V-twin oil

Primary Chain Case Oil Capacity:

1 US quart (0.95 liters)

Primary Chain Case Oil Type:

Harley-Davidson Primary Chain Case Lubricant or SAE 85W-140

Known Issues

Common Problems:

Carburetor tuning issues, potential starter clutch wear, exhaust header leaks, charging system issues on high-mileage units.

Maintenance Tips:

Regularly check and adjust primary chain tension. Ensure proper torque on exhaust header clamps. Keep electrical connections clean and sealed.

📚 Vehicle History

Brand Heritage

Foundation:

Founded in 1903, Harley-Davidson is one of America's oldest motorcycle manufacturers, known for its V-twin engines and cruiser motorcycles.

Model Evolution

Sportster Lineage:

The Sportster line, introduced in 1957, has evolved from a lightweight performance bike to a versatile platform. The Roadster variant, reintroduced in recent years, emphasizes sportier handling and braking.

Production

Manufacturing Location:

United States (Milwaukee, Wisconsin)

Model Year Specifics:

The 2007 model year saw continued refinement of the Evolution engine and chassis, with the Roadster offering a distinct performance-oriented package.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

While specific awards for the 2007 Roadster are scarce, the Sportster line is consistently recognized for its enduring appeal and customization potential.