2012 Harley-Davidson XL1200C Sportster Service & Repair Manual

IMPORTANT NOTICE Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures, specifications and service instructions in this manual are followed. Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. Harley-Davidson Motor Company

READER COMMENTS The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback -your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usability, and readability of this manual. Please list the page, item, and part number(s) of any errors you find in this manual. Please tell us how we can improve this manual. Occupation: Name: Dealership: Street: Department: e City: State: Zip: Gl J: 'S (.) 2012 Harley-Davidson Sportster Models Service Manual (99484-12A) Please clip out and mail to: Service Communications Department Harley-Davidson Motor Company P.O. Box653 Milwaukee, WI USA 53201

ABOUT THIS MANUAL GENERAL This service manual has been prepared with the following purposes in mind : To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair. To introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved major repair methods. We sincerely believe that this service manual will make your association with Harley-Davidson products more pleasant and profitable. HOW TO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual. NO. CHAPTER 1 Maintenance 2 Chassis 3 Engine 4 Fuel System 5 Drive/Transmission 6 Electrical A Appendix A Connector Repair B Appendix B Wiring c Appendix C Compensating Sprocket D Appendix D Conversions E Appendix E Glossary Use the TABLE OF CONTENTS (which follows this FORE- WORD) and the INDEX (at the back of this manual} to quickly locate subjects. Chapters and topics in this manual are sequentially numbered for easy navigation . For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS . For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. A number of acronyms and abbreviations are used in this document. See the E.1 GLOSSARY for a list of acronyms, abbreviations and definitions. PREPARATION FOR SERVICE PART NUMBER TOOL NAME HD-48650 DIGITAL TECHNICIAN II A wARNING Stop the engine when refueling or serv1cmg the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) Good preparation is very important for efficient service work. Start each job with a clean work area. This will allow the repair to proceed as smoothly as possible. It will also reduce the incidence of misplaced tools and parts. Clean a motorcycle that is excessively dirty before work starts. Cleaning will occa- sionally uncover sources of trouble. Gather any tools, instruments and any parts needed for the job before work begins. Interrupting a job to locate tools or parts is a distraction and causes needless delay. NOTES To avoid unnecessary disassembly, carefully read all related service information before repair work begins. In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly. When servicing a vehicle equipped with the Harley-Dav- idson Smart Security System (H-DSSS), it must first be disarmed. Keep the fob close to the vehicle or use DIGITAL TECHNICIAN II (Part No. HD-48650) to disable the system. Activate the system after service is completed. SERVICE BULLETINS In addition to the information presented in this manual, Harley- Davidson Motor Company will periodically issue service bulletins to Harley-Davidson dealers. Service bulletins cover interim engineering changes and supplementary information. C Consult the service bulletins to keep your product knowledge IV current and complete. O USE GENUINE REPLACEMENT PARTS 3: A wARNING w ~ 0 Harley-Davidson parts and accessories are designed for LL Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious injury. (00001 b) To achieve satisfactory and lasting repairs, carefully follow the service manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research , manufacturing, testing and inspecting experience. This is your assurance that the parts you are using will fit right, operate properly and last longer. WARNINGS AND CAUTIONS Statements in this manual preceded by the following words are of special significance. A wARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a) AcAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)

NOTICE NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b) NOTE Refers to important information, and is placed in italic type. It is recommended that you take special notice of these items. Proper service and repair is important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this manual are effective methods for performing service operations. A wARNING Always wear proper eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring com- pressors, slide hammers and similar tools. Flying parts could result in death or serious injury. (00496b) Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this manual. However, remember that these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury. Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous con - sequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-Dav- idson must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. Failure to do so could result in death or serious injury. PRODUCT REFERENCES A wARNING Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b) When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted. II FOREWORD Kent-Moore Products All tools mentioned in this manual with an "HD", "J" or "B" preface must be ordered through SPX Kent-Moore. For ordering information or product returns, warranty or otherwise, visit www.spx.com. Loctite Sealing and Threadlocking Products Some procedures in this manual call for the use of Loctite products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com. PRODUCT REGISTERED MARKS Apple, Alcantara S.p.A., Allen , Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse , Molex, Michelin , MPZ, Mulitilock, nano, NGK, Nevus, Packard, Pirell i, Permatex, Philips, PJ1 , Pozidriv, Robinair, S100, Sems, Snap-on, Teflon , Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto, XM Satellite Radio, and zumo are among the trademarks of their respective owners. H-D MICHIGAN, INC. TRADEMARK INFORMATION Bar & Shield, Cross Bones, Digital Tech, Digital Technician , Digital Technician II , Dyna, Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, Harley, Harley-Dav- idson , HD , Heritage Softail, Low Rider, Night Rod, Nightster, Night Train , Profile, Revolution, Road Glide, Road King , Road Tech , Rocker, Screamin' Eagle, Softail, Sportster, Street Glide, Street Rod , Sun Ray, Sunwash, Super Glide, SYN3, Tech link , Techlink II , Tour-Pak, Twin Cam 88, Twin Cam 88B, Twin Cam 96 , Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H-D Michigan, Inc. CONTENTS All photographs, illustrations and procedures may not neces- sarily depict the most current model or component, but are based on the latest production information available at the time of publication . Since product improvement is our continual goal, Harley-Dav- idson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.

MAINTENANCE 1.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter ............ ..... ......... .. .. 1-1 1.2 GENERAL Servicing a New Motorcycle .. ....................... ....... ........ .. ... .. 1-3 Safe Operating Maintenance ......... ....... .... ... ... .. ... ....... ........ 1-3 Shop Practices ............................................ .. ................ ...... 1-3 Repair Notes .. .... .. ............ ................ .. ........... .. ............ . 1-3 Safety ..... .. .. .... .. ......... ... .............. ................ ..... .... .. .. .... 1-3 Removing Parts .............................................. ...... .. .. ... 1-3 Cleaning ......... .... .. .. .... ...... .. ..................... .................... 1-3 Disassembly and Assembly .... ............................ .. .. .... 1-4 Checking Torques on Fasteners ........ .................... .. .... 1-4 Magnetic Parts Trays ............. .. ... ........ .... ............ ... ..... . 1-4 Repair and Replacement Procedures .......................... .. .... 1-4 Hardware and Threaded Parts .... .. .......... .................... 1-4 Threadlocking Agents ........ .................. .. ...................... 1-4 Wiring , Hoses and Lines .......................... .. .. .. .... .. .... .. .1-4 Instruments and Gauges ........................................... .. 1-4 Bearings .... ..... .. ... ................ ...... ....... ..... ....... .. ... .... ... ... 1-4 Bushings .. .... .......... ................ ...... ......... ....................... 1-4 Gaskets ...... .. ............................................ ... ................ 1-4 Lip-Type Seals ..... .. ....... ...... ..... .... .... ......... ... ....... .. ....... 1-4 O-Rings .... ........ ...... .... ...... .. ........................................ .1-5 Gears ...... ... ............. .. ..... ...................................... ..... ... 1-5 Shafts ..... ... ................... ........ ... ...... .. .... .... ......... ..... ..... . 1-5 Part Replacement. ................. ... ..... ..... ...... ............ ..... .. 1-5 Exhaust System Leakage .. ............ .... ..... ... .. ..... ..... ..... .1-5 Cleaning ............................................................. .. .. .. ..... ...... 1-5 Part Protection ............................................................. 1-5 Cleaning Process ......... ...... .. ....................................... 1-5 Rust or Corrosion Removal ...... .. .............. .. .. .............. .1-5 Bearings ...................................................................... 1-5 Tool Safety ..... ...... ..... ................... ... ... .... .... .. ... .. .. ... ....... ...... 1-5 Air Tools .. ... .. .. ....... .... ........... .. .... ..... .... ....... .. ... ....... ...... 1-5 Wrenches ......... ... .. .... .. ... ...... .. ....... .. ...... ..... ..... ... ... ...... 1-5 Pliers/Cutters/Pry Bars ................................ ... .... ... ...... 1-5 Hammers .. ...... .. ... .. .. ..... .......... ............. ... ..................... 1-6 Punches/Chisels .. .. .... .. ........ .... .. .. ............................. ... 1-6 Screwdrivers .......... .. ... .... ...... .... .... ...... .. .. ..... .......... ...... 1-6 Ratchets and Handles ... .... .. .................................. ... .. .1-6 Sockets ... ...... ..... .. .. ................. ...... ............................... 1-6 Storage Units ......... .... .... .. ............................................ 1-6 1.3 FUEL AND OIL Fuel ....... .... ....... ........ ........... ....... ........ ..... .. .. ... ...... ...... ......... 1-7 Gasoline Blends ................. .......... .................. ..................... 1-7 Engine Lubrication ........ ......... ... ...... .. ........ ....... ... .......... ...... 1-7 Winter Lubrication ... ................................... ......................... 1-8 1.4 BULB REQUIREMENTS Bulb Chart .......................... ... ...... .......... .. ..... ... .. .. .. ........ ...... 1-9 1.5 MAINTENANCE SCHEDULE General. ...... ................. ....... .. ........... ........ ...... ............ ....... 1-10 1.6 ENGINE OIL AND FILTER Checking and Adding Oil. .. .................. .. ........................... 1-14 Removing and Replacing Oil Filler Cap ........ .. .......... 1-14 Oil Level Cold Check .... ................ .... ........ .... ............. 1-14 Oil Level Hot Check ...... ........ .. ..................... .. ............ 1-15 Changing Oil and Filter .. ....... .................. .. .. .... ..... .. ...... ..... 1-15 Draining Oil Tank ..................................... .. ................ 1-15 Removing Oil Filter .. ...... ........ ...... .......... .. .................. 1-16 Installing Oil Filter ..... .. .... .. ................ ........... .............. 1-16 Refilling Oil Tank ...... ... .. ........... ......... ... ...................... 1-17 1.7 AIR FILTER XL Models except XL 1200V...................... ........ .. .. .. ........ 1-18 Removal ........ .... ............. ......................... ................ .. 1-18 lnstallation .............. .. .. ..... ...... .. .. .... ... ..................... ... .1-18 XL 1200V....... ... .... .... ...... ... .... ................. ....... ................... 1-18 Removal ....................... .. .... .... .. ...... ......................... .. 1-18 lnstallation ............ .... .. ......... .. ..... .......... ..................... 1-19 XR 1200X ................................ .. ..... .. ..... ............... ....... ..... 1-19 Removal ......... ... ........ ............ ...... .............................. 1-19 lnstallation ............. ............... ....... .. ......... .. ................. 1-20 Cleaning Filter Element.. ... ..... ........ ............ ................... ... 1-21 1.8 TIRES AND WHEELS Air Pressure .. ....... .. ... .... ....................................................1-22 Tire Replacement.. ...... ...... ............................................... 1-22 Tread Wear .... ... ........................... ... ...... ..................... 1-22 Tire Damage ............................ .. .... ..... ....... .... ........ ... .1-22 Specified Tires .... ......... ... .. .......... ................. .... ...... ....... .... 1-23 Wheel Bearings ...... .. .... ...... ..... .... ....... ....... .. .. .... ............... 1-23 Wheel Spokes .................. ........... ..... .. .. ... ............ .. ............ 1-23 Identify Wheel Spoke Groups ............ ........ ................ 1-23 Wheel Spoke Adjustment... ..................... .. .. .............. 1-23 1.9 PRIMARY CHAIN UJ 1- Freeplay Adjustment.. .. .... ...... .. .............................. .. ... ...... 1-25 Z 1.10 TRANSMISSION LUBRICANT ~ Transmission Lubrication ..... ............ .. ....... ...... ............... ... 1-26 Z Check Lubricant Level .................................. .......... .. .1-26 0 Change Lubricant. .. .. ...... .... .... .. .. ..... ..................... .. ... 1-27 0 1.11 CLUTCH LL 0 Adjustment.. ................. ........................... .... .. ...... ..... .. ....... 1-28 W Release the Clutch Cable Tension .. ....... .... ............... 1-28 ..J Clutch Adjustment. .. ..................................................1-28 [Q Lever Freeplay................................. .. ........... ... ........ .. 1-29 i! 1.12 DRIVE BELT AND SPROCKETS General. .................................. ... ............ .. ..... .. .................. 1-30 Cleaning ......... ........... ... ...... ......... .. .................................... 1-30 lnspection .............. ... ........ .. ..... ...... .. ... ...... .. .. ... .............. ... 1-30 Sprockets ..... .. ......................... .. ...... ... .... ............ .. .. .... 1-30 Idler Pulley: XR 1200X.............................................. 1-30 Drive Belt. .... ............................... ...... ... ... ......... ..... ..... 1-30 Checking Drive Belt Deflection .. .. ............................ ... ...... 1-31 General. ... ........... ..................... .. .. ...... ... .. .. .......... .. ..... 1-31 Gauging Deflection .. ....... .... ........ ............................... 1-31 Belt Deflection Adjustment. .......... ... .................................. 1-33 1.13 THROTTLE CONTROL Cable Inspection and Lubrication ...... .... .. ................ .. .. ..... 1-34 Cable Adjustment.. ... .. ...... .. ... .......................... .. .. ..... ........ 1-34 Operation ..... ........... ... ... ........................... .................. 1-34 Adjustment.. ......... ........ .................. .. ....... .... ...... ... ... ... 1-34 1.14 CABLE AND CHASSIS LUBRICATION General. .............................................. ..................... ...... ... 1-36 Cables and Hand Levers .. ............ .. .................................. 1-36 Foot Shift Lever and Rear Brake Pedal. ........................... 1-36 Jiffy Stand ................... ... .... ........... ......... ......... ............ ... ... 1-36 Steering Head Bearings ................ .................... .. ... .. ... ..... .1-36 Ill

2012 Harley-Davidson XL1200C Sportster Service & Repair Manual

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