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Harley Davidson Sportster 2012 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Year: 2012 👋 Introduction Market Position Category: Cruiser Motorcycle Target Audience: Harley-Davidson Sportster owners, independent mechanics, performance enthusiasts Competitive Analysis Key Competitors:...
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Type: Motorcycle
Vendor:
Sku: 436671
Harley Davidson Sportster 2012 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster
Year:
2012
👋 Introduction
Market Position
Category:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Sportster owners, independent mechanics, performance enthusiasts
Competitive Analysis
Key Competitors:
Indian Scout, Triumph Bonneville, Yamaha Bolt
Key Features
Distinctive Characteristics:
Iconic V-twin engine, customizability, legendary Harley-Davidson heritage
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Page Count:
776
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
V-Twin Evolution engine (all displacements for 2012 Sportster models: 883cc, 1200cc)
Transmission:
5-speed constant mesh
Electrical System:
Ignition, lighting, charging system, starter, battery, wiring diagrams
Fuel System:
Carburetor and Electronic Fuel Injection (EFI) systems
Brakes:
Hydraulic disc brakes (front and rear), ABS (if equipped)
Suspension:
Front fork (telescopic), rear shock absorbers
Frame And Bodywork:
Frame construction, body panels, fenders, seat, handlebars, controls
Wheels And Tires:
Wheel types, tire specifications, bearing maintenance
Cooling System:
Air-cooled engine with oil cooling considerations
Exhaust System:
Exhaust pipes, mufflers, emissions components
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups
Troubleshooting:
Diagnostic procedures for common and uncommon faults, fault codes
Repair:
Detailed step-by-step repair instructions for all major components
Disassembly And Assembly:
Complete instructions for component removal and reinstallation
Adjustments:
Carburetor/EFI tuning, clutch adjustment, brake bleeding
Wiring Diagrams:
Comprehensive, color-coded electrical schematics
Specifications And Tolerances:
Torque values, clearances, measurements for all components
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
📊 Manual Specifications
File Specifications
File Format:
Searchable PDF
Print Quality:
High-resolution, printable pages
Binding Type:
Digital (PDF Download)
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin Evolution
Displacement Options:
883cc (53.9 cu in), 1200cc (73.2 cu in)
Bore X Stroke 883Cc:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore X Stroke 1200Cc:
88.9 mm x 96.8 mm (3.50 in x 3.81 in)
Compression Ratio 883Cc:
8.7:1
Compression Ratio 1200Cc:
9.7:1
Valve Train:
Overhead valve (OHV), 2 valves per cylinder
Performance
Horsepower Approx 883Cc:
57 hp @ 6000 rpm (estimated)
Torque Approx 883Cc:
55 lb-ft @ 3500 rpm (estimated)
Horsepower Approx 1200Cc:
68 hp @ 6000 rpm (estimated)
Torque Approx 1200Cc:
71 lb-ft @ 3500 rpm (estimated)
Fuel System
Fuel Delivery Options:
Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV carburetor (depending on specific model variant)
Fuel Type:
Premium unleaded gasoline, minimum 91 octane
🔧 Transmission
Standard
Type:
5-speed, constant mesh
Clutch:
Wet, multi-plate
Final Drive:
Belt drive
📐 Dimensions
Exterior
Wheelbase Approx:
1500 mm (59.1 in)
Weights
Dry Weight Approx 883Cc:
255 kg (562 lbs)
Dry Weight Approx 1200Cc:
260 kg (573 lbs)
Gvwr Approx:
447 kg (985 lbs)
🛡️ Safety Features
Ratings
ABS Availability:
Optional on some 2012 models
Active Features
Braking System:
Hydraulic disc brakes, front and rear
Passive Features
Lighting:
Halogen headlight, LED tail light and brake light
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer (optional), odometer, trip meter, fuel gauge, indicator lights
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available as an option on select 2012 models.
Connectivity
Connectivity Features:
N/A (basic motorcycle instrumentation)
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months thereafter
Fluid Specifications
Engine Oil Type:
Harley-Davidson SYN3 (fully synthetic SAE 20W-50) or approved equivalent
Engine Oil Capacity 883Cc:
2.6 US quarts (2.5 L)
Engine Oil Capacity 1200Cc:
2.8 US quarts (2.6 L)
Transmission Oil Type:
Harley-Davidson Formula+ Transmission Oil (or approved equivalent)
Transmission Oil Capacity:
1 US quart (0.95 L)
Primary Chain Case Oil Type:
Harley-Davidson Formula+ Transmission Oil (or approved equivalent)
Primary Chain Case Oil Capacity:
1 US quart (0.95 L)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, brake pads, wheel bearings, primary chain tensioner
Potential Electrical Issues:
Regulator/rectifier failure, battery charging issues (addressed in manual diagnostics)
Engine Performance Tips:
Importance of proper carburation/EFI tuning and ignition timing for optimal performance and longevity
Part Numbers
Oil Filter Part Number Example:
63731-39B (for reference, specific models may vary)
📚 Vehicle History
Brand Heritage
Founder Year:
1903
Brand Philosophy:
American freedom, individuality, and the open road
Model Evolution
Introduction Year:
1957
Sportster Legacy:
Longest-running motorcycle nameplate in continuous production
Production
Manufacturing Location:
Milwaukee, Wisconsin, USA (primarily)
🏆 Awards & Recognition
Recognitions
Brand Awards:
Harley-Davidson consistently recognized for its iconic designs and brand loyalty.
Model Status:
The Sportster line is a cornerstone of the Harley-Davidson brand, celebrated for its versatility and enduring appeal.
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