🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster 1200

Model Year:

2009

Product Type:

Factory Service Repair Manual

Sportster Generation:

Evolution Engine, Rubber-Mounted Frame

👋 Introduction

Sportster Market Niche:

Cruiser motorcycle, known for its classic styling, V-twin rumble, and accessible performance.

2009 Sportster Positioning:

The 2009 Sportster 1200 represented a refined evolution of a long-standing platform, balancing tradition with modern fuel injection.

Key Competitors:

Indian Scout, Triumph Bonneville, various Japanese cruisers (e.g., Yamaha V-Star, Honda Shadow).

Engine Type:

Air-cooled, Evolution V-twin engine.

Frame Type:

Rubber-mounted frame for reduced vibration.

Fueling:

Electronic Sequential Port Fuel Injection (ESPFI).

Transmisson:

5-speed constant mesh transmission.

📋 Manual Details

Engine Coverage:

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

Transmission Coverage:

Detailed instructions for the 5-speed transmission, including clutch, primary drive, and gearbox components.

Electrical Coverage:

Comprehensive wiring diagrams, troubleshooting guides for ignition, lighting, charging, and starting systems.

Chassis Coverage:

Service procedures for frame, suspension (forks and rear shocks), steering, wheels, and tires.

Braking System Coverage:

Front and rear brake system repair, including master cylinders, calipers, rotors, and hydraulic lines.

Fuel System Coverage:

Information on fuel injection (EFI) system components, fuel pump, injectors, and related sensors.

Bodywork And Trim Coverage:

Procedures for body panel removal, installation, and related trim components.

Diagnostic Troubleshooting:

Extensive troubleshooting guides and diagnostic procedures for common and complex issues.

Estimated Page Count:

Hundreds of pages (specific number not provided in product info, but typical for factory manuals).

Manual Type:

Factory Service Repair Manual (FSM)

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Powertrain:

Engine, transmission, clutch, primary drive, final drive.

Electrical:

Ignition, lighting, charging system, starter, battery, instrumentation, and all wiring harnesses.

Chassis:

Frame, front suspension (forks), rear suspension (shocks), steering system, wheels, tires, and bearings.

Braking:

Front and rear disc brakes, hydraulic system, components.

Fuel And Emissions:

Fuel delivery system (EFI), fuel tank, fuel pump, fuel filter, evaporative emissions control.

Body And Fittings:

Body panels, fenders, seat, handlebars, controls, mirrors.

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, chain adjustment (if applicable), brake fluid service, etc.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for all major systems.

Repair And Rebuild:

Complete instructions for engine disassembly/assembly, transmission overhaul, suspension servicing, brake caliper rebuild, etc.

Component Replacement:

Detailed steps for replacing all major and minor components.

Adjustments:

Carburetor adjustment (if applicable, though 2009 is EFI), clutch adjustment, cable adjustments, steering head bearing adjustment.

Wiring Diagrams:

High-quality, detailed wiring schematics for all electrical systems.

Depth Of Coverage:

Comprehensive. Covers everything from routine maintenance and basic repairs to full engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic information, including torque specifications, tolerances, and repair procedures for EFI systems.

📊 Manual Specifications

File Format:

PDF

Print Quality Recommendation:

High resolution, suitable for printing individual pages or the entire manual.

Suggested Binding For Print:

Spiral-bound or three-ring binder for ease of use in a workshop environment.

Recommended Paper Type For Print:

Durable, coated paper for workshop conditions. Recommend printing specific sections as needed.

⚙️ Engine Specifications

Engine Type:

Evolution V-twin, air-cooled

Displacement:

1202 cc (73.4 cu in)

Bore X Stroke:

3.496 in x 3.811 in (88.8 mm x 96.8 mm)

Compression Ratio:

9.3:1

Cylinder Heads:

Aluminum

Cylinder Material:

Cast iron liners in aluminum cylinders

Valve Train:

Overhead Valves (OHV), 2 valves per cylinder

Camshaft:

Hydraulic lifters, pushrods

Claimed Horsepower:

Approx. 65-70 hp (specific figure varies by tuner, but this is typical for the era)

Claimed Torque:

Approx. 70-75 ft-lbs @ 3200 RPM (specific figure varies)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

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

🔧 Transmission

Transmission Type:

5-speed, constant mesh

Clutch Type:

Wet, multi-plate

Primary Drive:

Constant-mesh, 34/57 ratio

Final Drive:

Carbon fiber belt, 32/65 ratio

Transmission Fluid Type:

Harley-Davidson Formula+ (or equivalent API GL-4, SAE 20W-50 or SAE 75W-90)

📐 Dimensions

Overall Length:

Approx. 88.0 in (2235 mm)

Seat Height Laden:

Approx. 26.0 in (660 mm)

Ground Clearance:

Approx. 4.4 in (112 mm)

Dry Weight:

Approx. 575 lbs (261 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 932 lbs (423 kg)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically subject to the same standardized crash testing as automobiles; safety is dependent on rider skill and adherence to safe riding practices.

Braking System:

Dual disc front brakes, single disc rear brake.

Lighting System:

Halogen headlight, taillight, brake light, and turn signals.

Frame Design:

Steel frame with rubber engine mounts for vibration isolation.

💡 Technology Features

Instrumentation:

Analog speedometer with integrated tachometer (on some models/options), odometer, trip odometer, fuel level indicator, and engine diagnostics indicator lamp.

ABS:

ABS was an optional feature on select 2009 Sportster models.

Diagnostic Ports:

On-board diagnostics via a diagnostic port allowing connection to scan tools for reading fault codes and live data.

🔧 Maintenance

First Service:

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

Subsequent Engine Oil Change:

Every 5,000 miles (8,000 km) or 12 months.

Primary Chain Tensioner Inspection:

Check at every 1,000 miles service and annually thereafter. Replace if worn or faulty.

Spark Plug Replacement:

Every 10,000 miles (16,000 km).

Brake Fluid Replacement:

Every 24 months, regardless of mileage.

Engine Oil Type:

Harley-Davidson V-Twin 20W-50 Motorcycle Oil (or equivalent SAE 20W-50 API CG-4 or higher)

Engine Oil Capacity:

3.0 US qt (2.8 L) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Formula+ (or equivalent API GL-4, SAE 20W-50 or SAE 75W-90)

Primary Chain Case Oil Capacity:

2.2 US qt (2.1 L)

Transmission Oil Type:

Harley-Davidson Formula+ (or equivalent API GL-4, SAE 20W-50 or SAE 75W-90)

Transmission Oil Capacity:

0.9 US qt (0.85 L)

Brake Fluid Type:

DOT 4.

Primary Chain Tensioner:

The automatic primary chain tensioner can wear out, leading to noise and potential chain damage. Early models had a more robust design than some later replacements.

Carburetor Vs Efi Transition:

While EFI is generally reliable, early EFI systems can sometimes have issues with throttle position sensors (TPS) or fuel pump performance.

Wheel Bearings:

Like many motorcycles, wheel bearings can require periodic inspection and replacement, especially with frequent exposure to wet conditions.

📚 Vehicle History

Harley Davidson Heritage:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer with a rich history in performance, custom culture, and racing.

Sportster Lineage:

The Sportster line dates back to 1957, evolving through various engine displacements and chassis updates, becoming a fundamental part of Harley-Davidson's identity.

2009 Sportster Evolution:

The 2009 models represent a significant update with the introduction of Electronic Fuel Injection across the range, improving performance, emissions, and drivability over older carbureted models.

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin)

🏆 Awards & Recognition

Sportster Legacy:

The Sportster platform has consistently received positive reviews for its versatility, V-twin character, and customization potential, earning it a dedicated following and numerous accolades within the motorcycling press over its decades of production.