Segment:
Cruiser / Sportster Platform
Target Audience:
Harley-Davidson owners, independent repair shops, and enthusiasts seeking detailed service information.
Competitors:
Yamaha V-Star, Suzuki Boulevard, Honda Shadow.
Unique Selling Points:
Focus on the iconic Sportster platform, comprehensive coverage of the Evolution engine, detailed electrical schematics.
Manual Benefit:
Empowers owners and technicians with the knowledge to perform maintenance, repairs, and diagnostics efficiently.
Diagnostic Coverage:
Comprehensive diagnostics for all electrical and mechanical systems.
Repair Coverage:
Detailed step-by-step repair procedures for all major components and systems.
Maintenance Coverage:
Scheduled maintenance tasks, fluid changes, lubrication, and adjustments.
Estimated Page Count:
Approximately 500-700 pages (typical for a complete workshop manual).
Type:
Workshop Service Repair Manual
Engine:
Evolution 1200cc V-Twin engine, including internal components, cooling, lubrication, ignition, and fuel delivery.
Transmission:
5-speed constant mesh transmission, clutch assembly, primary drive, and final drive.
Electrical:
Complete electrical system, including battery, charging system, ignition system, lighting, instruments, and wiring diagrams.
Chassis:
Frame, suspension (front forks, rear shocks), steering, wheels, and tires.
Brakes:
Front and rear brake systems, including master cylinders, calipers, rotors, and hydraulic lines.
Fuel System:
Fuel tank, fuel lines, fuel pump, fuel injectors (EFI models), and throttle body.
Exhaust:
Exhaust pipes, mufflers, and heat shields.
Bodywork:
Fenders, fuel tank, seat, handlebars, and minor body components.
Disassembly Reassembly:
Detailed procedures for component removal, disassembly, inspection, repair, and reassembly.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.
Torque Specifications:
All critical torque specifications for fasteners and assembly points.
Adjustments:
Clutch adjustment, throttle cable adjustment, brake lever adjustment.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Depth:
Complete from basic maintenance to in-depth engine and transmission overhauls, electrical diagnostics, and chassis repairs.
Engine Type:
Air-cooled, Evolution V-Twin
Displacement:
1200cc (73.4 cu. in.)
Bore X Stroke:
3.500 in. x 3.812 in. (88.9 mm x 96.8 mm)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Ignition System:
High-performance electronic ignition with knock control
Horsepower Estimate:
Approximately 60-65 HP (at crank, dependent on specific tuning and exhaust)
Torque Estimate:
Approximately 67-70 ft-lbs (at crank, dependent on specific tuning and exhaust)
Fuel Tank Capacity:
3.1 US gallons (11.7 L)
Recommended Fuel:
91 octane or higher unleaded gasoline
Type:
5-speed, constant mesh
Primary Drive:
Chain, 34/46 ratio (1.353:1)
Final Drive:
Belt, 29/65 ratio (2.241:1)
Clutch Type:
Clutch: Wet, multi-plate, diaphragm spring
Transmission Fluid:
Harley-Davidson transmission lubricant or equivalent SAE 75W-90 synthetic gear oil
Crash Test Ratings:
Not typically rated by government agencies for motorcycles.
Braking System:
Hydraulic disc brakes, front and rear.
Lighting:
Halogen headlamp, LED tail lamp, incandescent turn signals.
Frame Construction:
Steel frame and swingarm for durability and stability.
Instrumentation:
Analog speedometer, digital tachometer, odometer, trip meter, fuel gauge, and indicator lights.
ABS:
Anti-lock Braking System (ABS) was an optional feature for the 2008 XL1200N.
Diagnostic Ports:
J1850 VpW diagnostic port for electronic diagnostics.
Initial Service:
First service at 1,000 miles (1600 km) or 6 months.
Subsequent Oil Changes:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Belt Tension Check:
Inspect and adjust belt tension every 2,500 miles (4,000 km).
Engine Oil Type:
Harley-Davidson V-Twin Oil (viscosity typically 20W-50) or equivalent.
Engine Oil Capacity:
Approximately 3.0 US quarts (2.8 L) with filter change.
Primary Chain Case Fluid:
Harley-Davidson primary chain case lubricant or SAE 20W-50 motorcycle oil.
Primary Chain Case Capacity:
Approximately 1 US quart (0.95 L)
Electrical Connections:
Potential for corrosion in electrical connectors, especially with aftermarket parts or in humid environments.
Primary Drive Tensioner:
Early Evolution engines had a hydraulic tensioner that could wear; manual tensioners are often preferred.
Suspension Harshness:
Some riders find the stock suspension can be a bit firm; upgrades are common.
Brand Focus:
American V-twin motorcycles, cruiser and touring segments.
Sportster Introduction:
The Sportster line was first introduced in 1957.
Evolution Engine Introduction:
The Evolution engine was introduced in 1984 for Sportster models.
Xl1200N Introduction:
The XL1200N 'Nightster' model was introduced for the 2007 model year, featuring a darker aesthetic.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri)
