2012 Harley Davidson Iron 883 66719 PDF

2012 IRON 883 Owner's Manual
Safety First
Safe Operating Rules
Motorcycles are different from other vehicles. They
operate, steer, handle and brake differently. Unskilled or
improper use could result in loss of control, death or
serious injury. (00556c)
Take a rider training course.
Read Owner's Manual before riding, adding accessories or servicing.
Wear a helmet, eye protection and protective clothing.
Never tow a trailer.
Before operating your new motorcycle it is your responsibility to read and follow the operating and
maintenance instructions in this manual, and follow these basic rules for your personal safety.
Know and respect the rules of the road. See Rules of the Road. Carefully read and
familiarize yourself with the motorcycle safety information that is provided by your country or
state. In the United States, read the RIDING TIPS booklet that is provided with your Owner's
Manual, and read through the MOTORCYCLE HANDBOOK which is made available by your
state.
Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls,
correct fuel and oil supply.
HarleyDavidson parts and accessories are designed for
HarleyDavidson motorcycles. Using nonHarleyDavidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)
Use only HarleyDavidson approved parts and accessories. Use of certain other
manufacturer's performance parts will void your new motorcycle warranty. See your Harley
Davidson dealer for details.
Stop the engine when refueling or servicing 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)
When refueling your motorcycle, the following rules should be observed.
Refuel in a well ventilated area with the engine turned off.
Remove fuel filler cap slowly.
Do not smoke or allow open flames or sparks when refueling or servicing the fuel system.
Do not fill fuel tank above the bottom of the filler neck insert.
Leave air space to allow for fuel expansion.
Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00003a)
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. (00004f)
Do not run motorcycle in a closed garage or confined area.
Inhaling motorcycle exhaust, which contains poisonous
carbon monoxide gas, could result in death or serious
injury. (00005a)
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not in
the full forward (down) position with vehicle weight on it,
the vehicle can fall over which could result in death or
serious injury. (00006a)
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
A new motorcycle must be operated according to the special breakin procedure. See
Breakin Riding Rules.
Operate motorcycle only at moderate speed and out of traffic until you have become
thoroughly familiar with its operation and handling characteristics under all conditions.
NOTE:
We recommend that you obtain information and formal training in the correct motorcycle riding
technique. In the United States, the Motorcycle Safety Foundation® offers beginning and
advanced rider safety courses. Call 8004469227 for information.
Travel at speeds appropriate for road and conditions and
never travel faster than posted speed limit. Excessive
speed can cause loss of vehicle control, which could
result in death or serious injury. (00008a)
Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High speed increases the influence of any other
condition affecting stability and increases the possibility of loss of control.
Pay strict attention to road surfaces and wind conditions and keep both hands on the
handlebar grips at all times when riding the motorcycle. Any two wheeled vehicle may be
subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement,
rough road surfaces, rider control error, etc. These forces may influence the handling
characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle
with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.
This may aggravate an unstable condition.
Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize
the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of
the vehicle and do not load bulky items too far behind the rider or add weight to the
handlebars or front forks. Do not exceed maximum specified load in each saddlebag.
NOTE:
New riders should gain experience under various conditions while driving at moderate speeds.
Operate your motorcycle defensively. Remember, a motorcycle does not afford the same
protection as an automobile in an accident. One of the most common accident situations
occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns
left into the oncoming motorcyclist. Operate only with headlamp on.
Wear an approved helmet, clothing, and foot gear suited for motorcycle riding. Bright or light
colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing
garments and scarves.
Avoid contact with exhaust system and wear protective
clothing that completely covers legs while riding. Exhaust
pipes and mufflers get very hot when engine is running
and remain too hot to touch, even after engine is turned
off. Failure to wear protective clothing could result in
burns or other serious injury. (00009a)
When carrying passengers, it is your responsibility to instruct them on proper riding
procedures. (See the RIDING TIPS booklet included in your HarleyDavidson Owner's Kit.)
Do not allow other individuals, under any circumstances, to operate your motorcycle unless
you know they are experienced, licensed riders and are thoroughly familiar with the
operation of your particular motorcycle.
Protect your motorcycle against theft. After parking your motorcycle, lock the steering head
and remove the key from the motorcycle.
Safe motorcycle operation requires alert mental judgment combined with a defensive driving
attitude. Do not allow fatigue, alcohol or drugs to endanger your safety or that of others.
Vehicles equipped with a sound system should have the volume adjusted to a non
distracting level before operating vehicle.
Maintain your motorcycle in proper operating condition in accordance with Regular Service
Intervals: 2012 Sportster Models. Proper care and maintenance, including tire
pressure, condition and tread depth plus proper adjustment to steering head bearings are
particularly important to the stability and safe operation of the motorcycle.
Do not operate vehicle with forks locked. Locking the forks
restricts the vehicle's turning ability, which could result in
Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could
Do not operate motorcycle with loose, worn or damaged
steering or suspension systems. Contact a Harley
Davidson dealer for repairs. Loose, worn or damaged
steering or suspension components can adversely affect
stability and handling, which could result in death or
Regularly inspect shock absorbers and front forks.
Replace leaking, damaged or worn parts that can
adversely affect stability and handling, which could result
in death or serious injury. (00012a)
Use HarleyDavidson replacement fasteners. Aftermarket
fasteners can adversely affect performance, which could
See your HarleyDavidson service manual for proper torque values.
Aftermarket fasteners may not have the specific property requirements to perform properly.
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a HarleyDavidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
in death or serious injury. (00014b)
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a HarleyDavidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)
Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can lead to component
failure and adversely affect stability, handling and
performance, which could result in death or serious injury.
(00016f)
GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of
the rider, passenger and cargo that can be safely carried.
The GVWR is shown on the information label, located on the frame steering head or the
frame downtube.
GAWR is the maximum amount of weight that can be safely carried on each axle.
Refer to weight table(s). See Specifications.
Do not tow a disabled motorcycle. Towing can adversely
affect stability and handling, which could result in death or
Do not pull a trailer with a motorcycle. Pulling a trailer can
cause tire overload, damage and failure, reduced braking
performance, and adversely affect stability and handling,
which could result in death or serious injury. (00018c)
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can
cause digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
defects or other reproductive harm. Wash hands after
handling. (00019e)
Do not open storage compartments while riding.
Distractions while riding can lead to loss of control, which
could result in death or serious injury. (00082a)
Consult a HarleyDavidson dealer regarding any questions
or problems that occur in the operation of your
motorcycle. Failure to do so can aggravate an initial
problem, cause costly repairs, cause an accident and
Be sure all equipment required by federal, state and local law is installed and in good
operating condition.
Rules of the Road
Keep to the right side of the road centerline when meeting other vehicles coming in the
opposite direction. Ride to left of center of your lane to avoid oily pavement ahead.
Always sound your horn, actuate your turn signals, and exercise caution when passing other
vehicles going in the same direction. Never try to pass another vehicle going in the same
direction at street intersections, on curves, or when going up or down a hill.
At street intersections give the rightofway to the vehicle on your right. Do not presume you
have the rightofway, as the other driver may not know it is your turn.
Always signal when preparing to stop, turn or pass.
All traffic signs, including those used for the control of traffic at intersections, should be
obeyed promptly. SLOW DOWN signs near schools and CAUTION signs at railroad
crossings should always be observed and your actions governed accordingly.
When intending to turn to the left, signal at least 100 feet 30.5 meters before reaching the
turning point. Move over to the centerline of the street (unless local rules require otherwise),
slow down, enter the intersection of the street and then turn carefully to the left.
Never anticipate a traffic light. When a change is indicated from GO to STOP in the traffic
control systems at intersections, slow down and wait for the light to change. Never run
through a yellow or red traffic light.
While turning either right or left, watch for pedestrians, animals, as well as vehicles.
Do not leave the curb or parking area without signaling. Be sure your way is clear to enter
moving traffic. A moving line of traffic always has the rightofway.
Be sure your license plate is installed in the position specified by law and is clearly visible at
all times. Keep the plate clean.
Ride at a safe speed that is consistent with the type of highway you are on. Pay strict
attention to whether the road is dry, oily, icy or wet.
Watch for debris such as leaves or loose gravel.
Weather and traffic conditions on the highway dictate adjusting your speed and driving
habits accordingly.
Accessories and Cargo
HarleyDavidson Motor Company cannot test and make specific recommendations concerning
every accessory or combination of accessories sold. Therefore, the rider must be responsible for
safe operation of the motorcycle when installing accessories or carrying additional weight.
See the Accessories and Cargo section in your owner's
manual. Improper cargo loading or accessory installation
can cause component failure and adversely affect stability,
handling and performance, which could result in death or
serious injury. (00021b)
(00016f)
The GVWR and GAWR are shown on the information label which is located on the frame
down tube in some destinations.
Do not pull a trailer with a motorcycle. Pulling a trailer can
cause tire overload, damage and failure, reduced braking
performance, and adversely affect stability and handling,
which could result in death or serious injury. (00018c)
Accessories and Cargo Guidelines
The following guidelines should be used when equipping a motorcycle, carrying passengers
and/or cargo.
Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High speed increases the influence of any other
condition affecting stability and increases the possibility of loss of control.
Pay strict attention to road surfaces and wind conditions and keep both hands on the
handlebar grips at all times when riding the motorcycle. Any two wheeled vehicle may be
subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement,
rough road surfaces, rider control error, etc. These forces may influence the handling
characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle
with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.
This may aggravate an unstable condition.
Keep cargo weight concentrated close to the motorcycle and as low as possible. This
minimizes the change in the motorcycle's center of gravity.
Distribute weight evenly on both sides of the vehicle.
Do not load bulky items too far behind the rider or add weight to the handlebars or front
forks.
Do not exceed maximum specified load in each saddlebag.
Luggage racks are designed for lightweight items. Do not overload racks.
Be sure cargo is secure and will not shift while riding and recheck the cargo periodically.
Accessories that change the operator's riding position may increase reaction time and affect
handling of the motorcycle.
Additional electrical equipment may overload the motorcycle's electrical system possibly
resulting in electrical system and/or component failure.
The front and/or rear guard(s) can provide limited leg and
cosmetic vehicle protection under unique circumstances.
(Fall over while stopped, very slow speed slide.) It is not
made or intended to provide protection from bodily injury
in a collision with another vehicle or any other object.
(00022a)
Large surfaces such as fairings, windshields, backrests, and luggage racks can have an
adverse affect on stability and handling.
Only properly installed Genuine HarleyDavidson accessories designed specifically for your
motorcycle model should be used.
Pay particular attention to the weights of accessories, cargo, riding gear, passenger and
rider and how the sum total of all these weights affect the loading capacity of your
motorcycle.
HarleyDavidson parts and accessories are designed for
HarleyDavidson motorcycles. Using nonHarleyDavidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)
Only Touring HarleyDavidson Motorcycles are suitable for
sidecar use. Consult a HarleyDavidson dealer. Use of
motorcycles other than Touring models with sidecars
Noise Control System
Tampering
Owners are warned that removal or replacement of any noise control system component may be
prohibited by law. This prohibition applies prior to vehicle sale or delivery to the ultimate
purchaser. Use of a vehicle on which noise control system components have been removed or
rendered inoperative may also be prohibited by law.
Identification
Vehicle Identification Number (VIN)
General
See Typical HarleyDavidson VIN: 2012 Sportster Models. A unique 17digit serial or
Vehicle Identification Number (VIN) is assigned to each motorcycle. Refer to HarleyDavidson
VIN Breakdown: 2012 Sportster Models.
Location
See VIN Locations: Sportster Models. The full 17digit VIN is stamped on the right side of the
frame near the steering head. In some destinations, a printed VIN label is also attached to the
right front downtube.
Abbreviated VIN
An abbreviated VIN showing the vehicle model, engine type, model year, and sequential number
is stamped on the left side of the crankcase between the engine cylinders.
NOTE:
Always give the full 17digit Vehicle Identification Number when ordering parts or making any
inquiry about your motorcycle.
1. Stamped VIN
2. VIN label
VIN Locations: Sportster Models
Typical HarleyDavidson VIN: 2012 Sportster Models
HarleyDavidson VIN Breakdown: 2012 Sportster Models
POSITION DESCRIPTION POSSIBLE VALUES

1 World manufacturer identifier 1HD=Originally manufactured for sale within
the United States
5HD=Originally manufactured for sale
outside of the United States
932=Originally manufactured in and for sale
only in Brazil market
MEG=Originally manufactured in and for sale
only in India market
2 Motorcycle type 1=Heavyweight motorcycle (901 cm3 or
larger)
4=Middleweight motorcycle (351 cm3 to 900
cm3)
3 Model See VIN model table
4 Engine type 2=Evolution® 883 cm3 aircooled, fuel
injected
3=Evolution® 1202 cm3 aircooled, fuel
injected
6=Evolution® 1202 cm3 precisioncooled,
fuelinjected
5 Introduction date/Configuration and Normal Midyear or Special
calibration recognition Introduction Introduction
1=Domestic 2, 4=Domestic
3=California 5, 6=California
A=Canada B=Canada
C=HDI D=HDI
E=Japan F=Japan
G=Australia H=Australia
J=Brazil K=Brazil
L=Asia Pacific M=Asia Pacific
N=India P=India
6 VIN check digit Can be 09 or X
7 Model year C=2012
8 Assembly plant C=Kansas City, MO U.S.A.
D=HD BrazilManaus, Brazil (CKD)
N=Haryana India (Bawal District Rewari)
9 Sequential number Varies
VIN Model Codes: 2012 Sportster Models
CODE MODEL NAME CODE MODEL NAME

CR XL 883L SuperLow® LD XR 1200X XR1200X™
CS XL 883R 883 Roadster LE XL 883N Iron 883™
CT XL 1200C 1200 Custom LF XL 1200V SeventyTwo™
CT XL 1200C 1200 Custom LF XL 1200V SeventyTwo™
CZ XL 1200N Nightster® LH XL 1200CP 1200 Custom
LC XL 1200X FortyEight™
Models and Features
Some models, features or configurations shown in this manual may not be available in all
markets.
Labels
See Labels for safety and maintenance labels which were on the vehicle when new. If removed,
replacement labels may be purchased for your motorcycle. Refer to Labels.
NOTE:
Some labels may be available in different languages for destinations outside the United States.
See a HarleyDavidson dealer for all labels available for purchase.
Labels
LABEL* PART DESCRIPTION LOCATION

NUMBER
1 1536801A Battery warning XL Models: Left side of
swingarm
XR 1200X: Top of belt
guard
2 Not sold Shock absorber label Rear of shock absorber
separately reservoir
(XR 1200X)
3 2914707 General warnings Top of air cleaner cover
(XL 883R, XL 883N, XL 1200N, XL 1200X,
XL 1200V)
2912795B General warnings Top of air cleaner cover
(XL 883L, XL 1200C, XL 1200CP)
2946608 General warnings Top of left side cover
(XR 1200X)
4 1537606A Battery removal/installation Inside left side cover
*See Labels.
Labels
Specifications
Specifications
NOTE:
Specifications in this publication may not match those of official certification in some markets due
to timing of publication printing, variance in testing methods, and/or vehicle differences.
Customers seeking officially recognized regulatory specifications for their vehicle should refer to
certification documents and/or contact their respective dealer or distributor.
Transmission
TRANSMISSION SPECIFICATION
Type Constant mesh, foot shift
Speeds 5 forward
Engine
ITEM XL 883 MODELS XL 1200 MODELS XR 1200X

Number of cylinders 2
Type 4cycle, 45 degree, Vtwin, air cooled
Compression ratio 8.91 9.71 10.01
Bore 3.000 in 76.20 mm 3.500 in 88.90 mm 3.500 in 88.90 mm
Stroke 3.812 in 96.82 mm 3.812 in 96.82 mm 3.812 in 96.82 mm
Displacement 53.9 in3 883 cm3 73.4 in3 1202 cm3 73.4 in3 1202 cm3
Electrical: XL Models
COMPONENT SPECIFICATION
Ignition timing Not adjustable
Battery 12 V, 225 CCA, 12 Ah,
sealed and maintenance free
Charging system Singlephase, 30 A system
(357 W @ 13.5 V, 2000 rpm,
405 W max power @ 13.5 V)
Spark plug type 6R12
Spark plug size 12 mm
Spark plug gap 0.0380.043 in 0.971.09 mm
Spark plug torque 1218 ftlbs 16.324.4 Nm
Electrical: XR 1200X
COMPONENT SPECIFICATION
Ignition timing Not adjustable
sealed and maintenance free
Charging system Singlephase, 30 A system
(357 W @ 13.5 V, 2000 rpm,
405 W max power @ 13.5 V)
Spark plug type 10R12X
Spark plug size 12 mm
Spark plug gap 0.0320.038 in 0.810.97 mm
Spark plug torque 1218 ftlbs 16.324.4 Nm
Sprocket Teeth
DRIVE ITEM NUMBER OF TEETH

XL 883 MODELS XL 1200 MODELS XR 1200X
U.S. WORLD U.S. WORLD U.S./WORLD JAPAN
Primary Engine 34 34 38 38 34 38
Clutch 57 57 57 57 57 57
Final Transmission 29 29 29 30 28 28
Rear wheel 68 68 68 68 68 68
Overall Drive Ratios
GEAR XL 883 MODELS XL 1200 MODELS XR 1200X

ALL U.S. WORLD U.S./WORLD JAPAN
1st 10.407 9.315 9.004 10.782 9.647
1st 10.407 9.315 9.004 10.782 9.647
2nd 7.436 6.653 6.432 7.702 6.891
3rd 5.530 4.948 4.783 5.728 5.125
4th 4.583 4.102 3.965 4.748 4.248
5th 3.931 3.517 3.400 4.071 3.643
Dimensions: XL 883 Models
ITEM XL 883R XL 883L XL 883N

in mm in mm in mm
Wheel base 60.0 1524 59.3 1506 59.8 1519
Road clearance 5.6 142 3.8 97 3.9 99
Seat height* 27.3 693 25.5 648 25.7 653
*With 180 lb 81.7 kg rider on seat.
Dimensions: XL 1200 Models and XR 1200X
ITEM XL 1200C XL 1200N XL 1200X XL 1200V XR 1200X

in mm in mm in mm in mm in mm
Wheel base 59.9 1521 59.8 1519 59.8 1519 60.0 1524 60.0 1524
Road clearance 4.4 112 3.9 99 3.9 99 4.7 120 5.9 150
Seat height* 26.6 676 25.7 653 26.0 660 26.6 675 29.2 742
*With 180 lb 81.7 kg rider on seat.
(00016f)
GVWR and GAWR are shown on the information plate, located on the frame down tube.
NOTE:
The maximum additional weight allowed on the motorcycle equals the Gross Vehicle Weight
Rating (GVWR) minus the running weight. For example, a motorcycle with GVWR of 1200 lbs 544
kg having a running weight of 800 lbs 363 kg , would allow a maximum of an additional 400 lbs
181 kg combined weight of the rider, passenger, riding gear, cargo and installed accessories.
Weights: XL 883 Models
ITEM XL 883L XL 883R XL 883N

lb kg lb kg lb kg
Running weight* 563 255.4 573 260.0 565 256.3
Maximum added weight allowed** 437 198.2 427 193.6 435 197.3
GVWR 1000 453.6 1000 453.6 1000 453.6
GAWR front 339 154.0 335 152.0 335 152.0
GAWR rear 661 300.0 665 301.6 665 301.6
*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this
weight.
Weights: XL 1200 Models and XR 1200X
ITEM XL 1200C XL 1200N XL 1200X XL 1200V XR 1200X

lb kg lb kg lb kg lb kg lb kg
Running weight* 582 264.0 562 254.9 567 257.2 555 251.7 573 259.9
Maximum added weight 418 189.6 438 198.7 433 196.4 445 201.8 427 193.7
allowed**
GVWR 1000 453.6 1000 453.6 1000 453.6 1000 453.6 1000 453.6
GAWR, front 335 152.0 335 152.0 335 152.0 335 152.0 340 154.2
GAWR, rear 665 301.6 665 301.6 665 301.6 665 301.6 660 299.4
*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this
weight.
Capacities: XL 883 Models
ITEM XL 883R XL 883L XL 883N

U.S. METRIC U.S. METRIC U.S. METRIC
Fuel tank (total) 3.3 gal 12.5 L 4.5 gal 17.0 L 3.3 gal 12.5 L
Oil tank with filter 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L
Transmission (approximate) 1.0 qt 0.95 L 1.0 qt 0.95 L 1.0 qt 0.95 L
Low fuel warning light on 0.8 gal 3.0 L 1.0 gal 3.8 L 0.8 gal 3.0 L
Capacities: XL 1200 Models and XR 1200X
ITEM XL 1200C XL 1200N XL 1200X/V XR 1200X

U.S. METRIC U.S. METRIC U.S. METRIC U.S. METRIC
Fuel tank (total) 4.5 gal 17.0 L 3.3 gal 12.5 L 2.1 gal 7.9 L 3.5 gal 13.2 L
Oil tank with filter 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L
Oil tank with filter 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L 2.8 qt 2.6 L
Transmission 1.0 qt 0.95 L 1.0 qt 0.95 L 1.0 qt 0.95 L 1.0 qt 0.95 L
(approximate)
Low fuel warning light 1 gal 3.8 L 0.8 gal 3.0 L 0.65 gal 2.5 L 0.8 gal 3.0 L
Bulb Chart
LAMP DESCRIPTION BULBS CURRENT HARLEY

DRAW DAVIDSON
(ALL LAMPS 12 V) REQUIRED
(AMPERAGE) PART
NUMBER
Headlamp High beam/low beam 1 5.0/4.58 6832903
Position lamp international 1 0.32 5343697
Tail and stop Tail and stop lamp (XL 1 LED assembly
lamps 1200C/CP)*
Tail and stop lamp (all other 1 2.10/0.59 6816704
models)
Turn signal Front/running 2 2.25/0.59 6816889A
lamp Front international 2 1.75 6816384
Rear (Domestic XL 883N, XL 2 2.25 6816889A
1200N/X/V)**
Rear (Canada XL 883N, XL 2 2.25 6857264B
1200X/N)
Rear (HDI XL 883R, XL 2 LED assembly
1200X/N/V)***
Rear (all other models) 2 1.75 6816384
Instrument Illuminated with LEDs. Replace entire assembly upon failure.
panel
* XL 1200C/CP tail and stop lamp is illuminated with LED's. Replace entire assembly upon
failure.
** Functions as turn signal, tail and stop lamps.
*** This is an LED assembly. Replace entire assembly upon failure.
Tires: 2012 Sportster Models
MODEL MOUNT DIAMETER SPECIFIED TIRE PRESSURE (cold)

psi kPa
XL 883L front 18 Michelin Scorcher "11F" 120/70ZR18 36 248
rear 17 Michelin Scorcher "11" 150/60ZR17 42 290
XL 883R/N front 19 Michelin Scorcher "31" 100/90B19 30 207
XL 1200N rear 16 Michelin Scorcher "31" 150/80B16 40 276

XL 1200X/C/CP front 16 Michelin Scorcher "31" 130/90B16 36 248
rear 16 Michelin Scorcher "31" 150/80B16 40 276
XL 1200V front 21 Dunlop D402F MH9021 30 207
rear 16 Dunlop D401 150/80/B16 40 276
XR 1200X front 18 Michelin Scorcher "11F" 120/70ZR18 36 248
rear 17 Michelin Scorcher "11" 180/55ZR17 42 290
Tire Data
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a HarleyDavidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
Use only HarleyDavidson specified tires. See a Harley
Davidson dealer. Using nonspecified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
Always match recommended tires. Do not mix specified tire brands. Refer to Tires: 2012
Sportster Models.
Tubeless tires are used on all HarleyDavidson cast and disc wheels. Tubeless tires fitted with the
correct size inner tubes may be used on HarleyDavidson laced (wire spoked) wheels. Tire sizes
are molded on the tire sidewall. Inner tube sizes are printed on the tube.
HarleyDavidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Replace tire immediately with a HarleyDavidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)
HarleyDavidson does not perform any testing with only nitrogen in the tires. HarleyDavidson
neither recommends nor discourages the use of pure nitrogen to inflate tire.
India Tire Compliance Statement: HarleyDavidson Motor Company declares that the tires listed
in the specifications section meet the Indian Standard 15627 requirement of the Bureau of Indian
Standards (as amended from time to time) required for registration of vehicles assembled in India.
These tires also comply with the Central Motor Vehicle Rules requirements, 1989.
Gasoline Blends
Your motorcycle was designed to get the best performance and efficiency using unleaded
gasoline. Most gasoline is blended with alcohol and/or ether to create oxygenated blends. The
type and amount of alcohol or ether added to the fuel is important.
Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)
Gasoline/METHYL TERTIARY BUTYL ETHER (MTBE) blends are a mixture of gasoline and
as much as 15% MTBE. Gasoline/MTBE blends use in your motorcycle is approved.
ETHANOL fuel is a mixture of ethanol (grain alcohol) and unleaded gasoline and can have
an impact on fuel mileage. Fuels with an ethanol content of up to 10% may be used in your
motorcycle without affecting vehicle performance. U.S. EPA regulations currently indicate
that fuels with 15% ethanol (E15) are restricted from use in motorcycles at the time of this
publication. Some motorcycles are calibrated to operate with higher ethanol concentrations
to meet the fuel standards in certain countries.
REFORMULATED OR OXYGENATED GASOLINES (RFG) describes gasoline blends that
are specifically designed to burn cleaner than other types of gasoline. This results in fewer
tailpipe emissions. They are also formulated to evaporate less when filling the tank.
Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run
normally using this type of fuel. HarleyDavidson recommends using it whenever possible as
an aid to cleaner air in our environment.
Do not use racing fuel or fuel containing methanol. Use of these fuels will damage the fuel
system.
The only octane booster HarleyDavidson recommends is SCREAMIN' EAGLE SUPER
OCTANE BOOST. This is the only octane booster that has been extensively tested and
approved for use with HarleyDavidson engines and components.
Some gasoline blends might adversely affect starting, driveability or fuel efficiency. If any of these
problems are experienced, try a different brand of gasoline or gasoline with a higher octane blend.
Fuel
Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump.
Refer to Octane Ratings.
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making
air entrapment and pressurization a possibility.
Octane Ratings
SPECIFICATION RATING
Pump Octane (R+M)/2 91 (95 RON)
Catalytic Converters
Certain international destination model motorcycles are equipped with catalytic converters.
Do not operate catalytic converterequipped vehicle with
engine misfire. If you operate the vehicle under this
condition, the exhaust will become abnormally hot, which
can cause vehicle damage, including emission control
loss. (00149c)
Use only unleaded fuel in catalytic converterequipped
motorcycles. Using leaded fuel will damage the emission
control system. (00150b)
Controls and Indicators
General: Controls and Indicators
Read the CONTROLS AND INDICATORS section before
riding your motorcycle. Failure to understand the
operation of the motorcycle could result in death or
Some features explained are unique to certain models. These features may be available as
accessories for your HarleyDavidson motorcycle. See a HarleyDavidson dealer for a complete
list of accessories that will fit your specific motorcycle.
Ignition Switch
The automaticon headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
See Ignition Switch: Sportster Models. The ignition switch controls electrical functions of the
motorcycle. The switch is located on the right side of the steering head. Refer to Ignition
Switch.
Turn the key to the OFF position and remove key when the motorcycle is not in operation. The
key may also be removed in the ACC position.
NOTES:
Write the ignition key number in the space provided at the front of this manual.
The lamps work when the switch is in the IGNITION position, as required by law in some
localities.
Protect your vehicle against theft. Failure to lock the
motorcycle after parking could result in theft and/or
equipment damage. (00151b)
Do not lubricate barrel locks with petroleum based
lubricants or graphite. Inoperative locks may result.
(00152a)
Turn the ignition switch to the OFF position before locking
the motorcycle. Leaving the switch in the ACC position will
keep the instrument lights on and result in a discharged
battery. (00492b)
1. Ignition off
2. Accessory on
3. Ignition on
Ignition Switch: Sportster Models
Ignition Switch
SWITCH FUNCTION
POSITION
OFF Ignition and lamps are off. Key may be removed.
ACC.* Instrument lamps are on. Brake lamp and horn can be activated. Key may be
removed.
IGNITION Ignition and lamps are on.
*International models: position lamp and tail lamp are also on.
Hand Controls: Basic Operation
Electric Starter Switch
NOTE:
The OFF/RUN switch MUST be in RUN position to operate engine.
See Handlebar Controls. The electric starter switch is located on the right handlebar control
group. See Starting the Engine for detailed operation procedures.
1. Put the engine OFF/RUN switch in the RUN position and the transmission in neutral. Neutral
(green) indicator lamp should be illuminated.
2. See Ignition Switch: Sportster Models. Turn ignition switch to IGNITION and push the
START switch to operate starter motor.
Engine OFF/RUN Switch
See Handlebar Controls. The engine OFF/RUN switch (7) turns the ignition power ON or OFF.
The engine OFF/RUN switch is located on the right handlebar control. Push the top portion of the
engine OFF/RUN switch to turn off ignition power and shut the engine off. Push the bottom portion
of the engine OFF/RUN switch to turn on ignition power.
NOTES:
The engine OFF/RUN switch must be in the RUN position to start or operate the engine.
The engine OFF/RUN switch should be used to shut the engine off.
1. To shut the engine off, push the top of the OFF/RUN switch to the OFF position.
2. See Ignition Switch: Sportster Models. Turn the ignition key to the OFF position to turn
the ignition power completely OFF.
Throttle Control Grip
See Handlebar Controls. The throttle control grip (9) is located on the right handlebar control
and is operated with the right hand.
To reduce rider fatigue on long trips, a springloaded throttle friction adjustment screw (10) is
located at the bottom of the throttle grip clamp on noncruise equipped models.
1. Slowly turn throttle control grip clockwise (toward the front of the motorcycle) to close the
throttle (decelerate).
2. Slowly turn throttle control grip counterclockwise (toward rear of motorcycle) to open the
throttle (accelerate).
Do not tighten throttle friction adjustment screw to the
point where the engine will not return to idle automatically.
Overtightening can lead to loss of vehicle control, which
could result in death or serious injury. (00031b)
3. Loosen the throttle friction adjustment screw so the throttle returns to the idle position when
the hand is removed from the grip.
4. Screw the throttle adjustment screw in to increase friction on grip. This provides a damping
effect on throttle motion.
NOTE:
The throttle friction adjustment screw should not be used under normal stop and go operating
conditions.
Clutch Hand Lever
Do not position fingers between hand control lever and
handlebar grip. Improper hand positioning can impair
control lever operation and cause loss of vehicle control,
See Handlebar Controls. The clutch hand lever (1) is located on the left handlebar and is
operated with the fingers of the left hand.
1. Slowly pull clutch hand lever in against handlebar grip to fully disengage clutch.
2. Shift to first gear using the gear shifter lever. See Gear Shift Lever.
3. Slowly release the clutch hand lever to engage clutch.
A clutch switch is incorporated into the left handlebar switch assembly. It enables the rider to start
the vehicle in any gear (or in neutral) as long as the clutch lever is pulled in. If the clutch is not
disengaged and the vehicle is in gear, the vehicle will not start.
Horn Switch
See Handlebar Controls. The horn is operated by pushing on the horn switch (2) located on the
left handlebar control.
Headlamp Dimmer Switch
See Handlebar Controls. The headlamp dimmer switch (3) is located on the left handlebar. The
switch has two positions to activate the headlamps high or low beams.
Press the top of the headlamp dimmer beam switch to activate the high beam.
Press the bottom of the headlamp dimmer switch to return to the low beam.
See Indicator Lamps (Typical). The (blue) high beam indicator lamp will illuminate when the
high beam is on.
Turn Signal Switches
See Handlebar Controls. Each handlebar control group contains a turn signal switch.
The right turn signal switch (11) operates the right front and right rear flashing lamps.
The left turn signal switch (4) operates the left front and left rear flashing lamps.
NOTE:
Front turn signal lamps also function as running lamps. Due to local regulations, this feature may
not be available in all locations.
1. Clutch hand lever
2. Horn switch
3. Headlamp dimmer switch
4. Left turn signal switch
5. Master cylinder reservoir
6. Electric starter switch
7. Engine off/run switch
8. Brake hand lever
9. Throttle control grip
10. Throttle friction adjusting screw
11. Right turn signal switch
Handlebar Controls
Turn Signal Switch Operation
The turn signal switches are used by the turn signal module to control turn signal operation based
on vehicle speed, vehicle acceleration and turn completion.
Momentarily press the desired turn signal switch. The turn signal lamps will begin and continue
flashing until they are manually or automatically cancelled. As long as the motorcycle is
stationary, the signals will flash.
NOTES:
If you are signaling to turn in one direction and you press the switch for the opposite turn
signal, the first signal is cancelled and the opposite side begins flashing.
If you want to stop the lamps from flashing, briefly press the turn signal switch a second
time. The turn signal lamps will stop flashing.
If a turn signal indicator is flashing at a high rate, a turn signal bulb is not operating. Exercise
caution and use hand signals. Replace defective components immediately.
Hazard Warning 4Way Flasher
Use the following method to activate the fourway flashers.
1. With the ignition key on and security system disarmed (if equipped), press the left and right
turn signal switches at the same time.
2. Turn the ignition key off. The security system will automatically arm, if equipped, and the
fourway flashers will continue for two hours.
3. To cancel fourway flashing, disarm the security system if necessary, turn the ignition key on
and press the left and right turn signal switches at the same time.
This system allows a stranded motorcycle to be left in the fourway flashing mode and secured
until help is found.
Instruments
Speedometer
XL Models: See Instruments: XL Models.
XR 1200X: See Instruments: XR 1200X.
The speedometer registers miles per hour (U.S. models) or kilometers per hour (international
models) of forward speed. The speedometer also provides the following selectable functions:
Odometer
Trip odometers A and B
12 or 24 hour clock
The speedometer has a single display window for the above functions.
1. See Function Switch (typical). Pressing the function switch (on back of speedometer)
with the ignition switch in any position will activate the odometer reading and time. Time and
mileage or kilometers may be checked without unlocking ignition switch. Press and release
function switch (on back of speedometer) once to view odometer. Press and release button
again to display time.
2. To check mileage on trip odometers, the ignition switch must be in the ACC or IGNITION
position. Press and release the function switch (on back of speedometer) until the desired
trip odometer reading is displayed. An A or B in the upper left of the display window
identifies trip odometers.
3. To reset or zero trip odometers, have desired (A or B) odometer in display window. Press
function switch (on back of speedometer) and hold button for 23 seconds. The trip
odometer will be reset to zero.
4. Repeat the previous step if you wish to zero both trip odometers.
Setting Clock
1. Turn the ignition switch to ACC or IGNITION.
2. See Function Switch (typical). Press and release function switch (on back of
speedometer) until time (hour and minutes) is displayed. Press and hold the function switch
for five seconds or until 12HR begins to blink in the speedometer display window. Release
the button.
3. Press and release the function switch (on back of speedometer) once to advance to a
blinking 24HR military style time display. Each time you press and release the button, the
display will switch between 12HR and 24HR.
4. When the desired time style is displayed, press and hold the function switch (on back of
speedometer) for five seconds. The display will switch to the time display with the hours
blinking.
5. Press and release the button repeatedly to advance the hours. Each time you press and
release the button, the display will advance one hour.
NOTE:
No AM or PM time setting is required. When the correct hour is reached, press and hold
function switch to advance to minute setting.
6. When the correct hour is displayed, press and hold the button for five seconds. The minutes
display will start blinking.
7. Press and release the button repeatedly to advance the minutes display. Each time you
press and release the button, the display will advance one minute.
8. When the correct minutes are displayed, press and hold the button for five seconds. The
minutes display will stop blinking, indicating that the clock has been set.
9. Turn the ignition switch OFF.
Tachometer
See OPERATING RECOMMENDATIONS section. Do not
operate the engine above maximum safe RPM as shown
under OPERATION (red zone on tachometer). Lower the
RPM by upshifting to a higher gear or reducing the amount
of throttle. Failure to lower RPM may cause equipment
damage. (00159a)
The tachometer (if applicable) registers the engine speed in revolutions per minute (RPM).
Tip Indicator Lamp
If tip occurs, check all controls for proper operation.
Restricted control movement can adversely affect the
performance of the brakes, clutch or ability to shift, which
could result in loss of vehicle control and death or serious
injury. (00350a)
Should motorcycle be tipped over, the word "tip" will appear in the odometer window. Engine will
not start until reset. To reset, cycle ignition/headlamp key switch IGNITIONOFFIGNITION.
1. Speedometer
2. Odometer
3. Security system lamp
4. Battery lamp
5. Low fuel lamp
6. Check engine lamp
Instruments: XL Models
Selecting Instrument Units: XR 1200X
On XR 1200X, units displayed in the instruments can be selected between miles and kilometers.
1. Turn the ignition switch to the ACC or IGNITION position.
2. Press the function button to select the odometer display screen.
3. Press and hold the function button until the units change (miles/kilometers).
4. To change the units again, release function button, then press and hold until units change
again.
1. Speedometer
2. Tachometer
3. Odometer
4. Security system lamp
5. Battery lamp
6. Low fuel lamp
7. Check engine lamp
8. Temperature lamp
Instruments: XR 1200X
Function Switch (typical)
Instrument Lamps
XL Models: See Instruments: XL Models.
XR 1200X: See Instruments: XR 1200X.
Warning lamps are located on the instrument face.
Engine Check Lamp
The engine check lamp indicates whether the engine/engine management system is operating
normally. The engine lamp color is amber.
The engine lamp normally comes on when the ignition is first turned on and remains on for
approximately 4 seconds, as the engine management system runs a series of selfdiagnostics.
If the engine lamp comes on at any other time, see a HarleyDavidson dealer.
Low Fuel Lamp
Refer to Capacities: XL 883 Models. The low fuel lamp indicates when fuel falls below the
reserve level in the fuel tank. The low fuel lamp color is amber.
The low fuel lamp will not turn off until there is sufficient fuel in the tank, the ignition switch has
been turned off and back on, and the vehicle has begun forward speed. If the low fuel lamp
remains lit with sufficient fuel in the tank, there may be an issue with the fuel sender. See a
HarleyDavidson dealer.
Battery Lamp
The red battery charging lamp indicates either overcharging or undercharging of the battery. Refer
to Battery.
Security System Lamp
The red security system lamp indicates when the security system is armed. Refer to Harley
Davidson Smart Security System.
If the lamp remains lit longer than four seconds, the security module may need to be serviced.
See a HarleyDavidson dealer.
Temperature Lamp: XR 1200X
The red temperature lamp indicates extreme high temperatures. Stop the engine immediately and
allow the engine to cool down. See a HarleyDavidson dealer if the condition persists.
Indicator Lamps
See Indicator Lamps (Typical). Five indicator lamps are provided.
The left and right green TURN indicators, located on the ends of the indicator bar, flash
when a turn signal is activated. When the 4way hazard flashers are operating, both turn
indicators will flash simultaneously.
The blue BEAM indicator lamp, when lit, signals high beam headlamp operation.
The green NEUTRAL lamp, when lit, signals the transmission is in neutral gear.
The red OIL indicator lamp, when lit, signals that oil is not circulating through the engine.
NOTE:
The OIL indicator lamp will glow when the ignition is turned on prior to starting engine. With
engine running, lamp should be off when engine speed is above idle.
Several other circumstances that could cause the red oil indicator lamp to signal, include the
following:
If the oil pressure indicator lamp does not go off at speeds above idling, it is usually because
of an empty oil tank or diluted oil.
In freezing weather the oil feed may clog with ice and sludge, preventing oil circulation.
A grounded oil signal switch wire.
A faulty signal switch.
A damaged or improperly installed check valve.
Trouble with the pump.
If the oil pressure indicator lamp remains lit, always check
the oil supply first. If the oil supply is normal and the lamp
is still lit, stop the engine at once and do not ride further
until the trouble is located and the necessary repairs are
made. Failure to do so may result in engine damage.
(00157a)
1. Left turn
2. High beam
3. Neutral
4. Oil
5. Right turn
Indicator Lamps (Typical)
Gear Shift Lever
Location
See Shift Lever and Shift Pattern. The gear shift lever is located on the left side of the
motorcycle and is operated with the left foot. The shift lever changes gears in a sequential five
speed transmission.
Shift Pattern
The clutch must be fully disengaged before attempting a
gear shift. Failure to fully disengage the clutch can result
in equipment damage. (00182a)
See Shift Lever and Shift Pattern. Each gear must be engaged in sequence. Lift the gear shift
lever to upshift and press the lever to downshift. After each gear change, release the gear shift
lever to allow it to return to its resting position. See Shifting Gears.
Neutral
Neutral is located between first and second gear. The transmission can be shifted to neutral from
either first or second gear. Lift or press the gear shift lever 1/2 of its stroke. In neutral, the
indicator lamp will light.
Shift Lever and Shift Pattern
Brake System
Do not apply brake strongly enough to lock the wheel. A
locked wheel will skid and can cause loss of vehicle
control, which could result in death or serious injury.
(00053a)
The rear brake pedal controls the rear wheel brake and is located on the motorcycle's right side.
Operate the rear brake pedal with the right foot.
The front brake hand lever controls the front wheel brake and is located on the right handlebar.
Operate the hand lever with the fingers of the right hand.
Do not position fingers between hand control lever and
handlebar grip. Improper hand positioning can impair
control lever operation and cause loss of vehicle control,
Brakes should be applied uniformly and evenly to prevent wheels from locking up. A balance
between rear and front braking is generally best.
Jiffy Stand
Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result in
The jiffy stand is located on the left side of the motorcycle and swings outward to support the
motorcycle for parking.
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not in
the full forward (down) position with vehicle weight on it,
the vehicle can fall over which could result in death or
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
Jiffy Stand Interlock: International Models
Some international models have a jiffy stand interlock.
The motorcycle will start and run with the jiffy stand down while the transmission is in neutral. If
the jiffy stand is down and the transmission in gear, engaging the clutch stalls the motorcycle. The
message "SidE StAnd" will scroll across the odometer. Raising the jiffy stand or putting the
transmission in neutral, will permit the engine to run. The odometer will clear the message.
If the stand lowers at a speed greater than 10 mph 15 km/h , the engine will continue to run. It will
illuminate the indicators (flash twice) and scroll the message "SidE StAnd" across the odometer.
The message will remain until the system detects the jiffy stand in the fully retracted position
again. The rider may continue to ride while in this mode.
The rider may clear the text messages at any time by pressing the function switch once while the
vehicle is powered up.
Rear View Mirrors
Objects in mirrors are closer than they appear. Use caution
when judging distance of objects in mirrors. Failure to
judge correct distances could result in death or serious
injury. (00033a)
Your vehicle is equipped with two convex rear view mirrors.
This type of mirror is designed to give a much wider view to the rear than a flat mirror. However,
cars and other objects seen in this type of mirror will look smaller and farther away than they
actually are.
Use caution when judging the size or relative distance of objects seen in rear view mirrors.
Always adjust the rear view mirrors to clearly reflect the area behind the motorcycle before
riding.
NOTE:
Adjust mirrors so you can see a small portion of your shoulders in each mirror. This will help you
establish the relative distance of vehicles to the rear of your motorcycle.
Rear View Mirrors: XL 1200X
Improperly aligned handlebars or components can contact
the fuel tank when turned to the left or right. Contact with
the fuel tank can cause cosmetic damage. (00372b)
See Rear View Mirror: XL 1200X. When adjusting mirrors, slowly turn handlebars to the full
right and full left positions to make sure the mirrors do not contact the fuel tank.
Rear View Mirror: XL 1200X
Fuel Filler Cap
General
See SAFE OPERATING RULES section and review safety procedures listed below.
Do not spill fuel onto the motorcycle while refueling.
Immediately wipe up fuel spills on your motorcycle. Fuel
can cause damage to cosmetic surfaces. (00147b)
Use only unleaded fuel in catalytic converterequipped
motorcycles. Using leaded fuel will damage the emission
control system. (00150b)
Do not use aftermarket fuel caps. Aftermarket fuel caps
may fit improperly and leak, which could lead to death or
serious injury. See a HarleyDavidson dealer for approved
fuel caps. (00034a)
XL Models
See Fuel Filler Cap: XL Models. To open, turn fuel filler cap counterclockwise and lift up. To
close, turn fuel filler cap clockwise until it clicks. The ratchet action of the cap prevents
overtightening.
NOTE:
Fuel filler cap turns approximately a 3/4 turn before it starts unscrewing.
Fuel Filler Cap: XL Models
XR 1200X
See Fuel Filler Cap: XR 1200X. To open fuel filler cap, pull metal tab up, turn tab
counterclockwise and remove cap. To close, insert fuel filler cap, turn tab clockwise and push tab
down.
Fuel Filler Cap: XR 1200X
Fork Lock
Protect your vehicle against theft. Failure to lock the
motorcycle after parking could result in theft and/or
equipment damage. (00151b)
See Fork Lock Location: Sportster Models. Sportster models have the fork lock located on
the steering head just above the ignition switch. Using the fork lock immediately after parking your
motorcycle will discourage unauthorized use or theft when parking your motorcycle.
To lock fork, see Fork Lock Positions: Sportster Models.
1. Turn fork to full left position.
2. Insert ignition key into fork lock.
3. Turn to right position (clockwise).
4. Remove ignition key.
Fork Lock Location: Sportster Models
1. Fork locked
2. Fork unlocked
Fork Lock Positions: Sportster Models
Suspension Definitions
Damping: Resistance to velocity of suspension movement. Damping affects how easily the
suspension can move and limits oscillations of the system once movement has begun.
Compression: The suspension is compressed when the wheel moves upward (when riding over
a bump).
Rebound: The suspension is rebounding when it is moving back from being compressed
(rebounding to the road surface after a bump).
Vehicle Sag: The amount the rear shock and fork springs are compressed by the weight of the
motorcycle.
Rider Sag: The amount the rear shock and fork springs are compressed by the weight of the rider
on the motorcycle.
Preload: An adjustment made to the rear shock and front fork springs to limit vehicle and rider
sag to a standard percentage of total suspension travel.
Before evaluating and adjusting suspension settings, check the motorcycle's tires. They must be
in good condition and properly inflated. Refer to Tires: 2012 Sportster Models.
Tool Kit: XR 1200X
A tool pouch is provided with suspension adjustment tools:
5 mm hex key (front fork preload adjustment)
Spanner wrench with extension handle (shock absorber preload adjustment)
General Suspension Adjustment: XR 1200X
The front and rear preload setting will need to be adjusted for the rider's weight and cargo. This
adjustment should be made before the motorcycle is ridden any distance and after changing the
overall vehicle weight (adding saddlebags, etc.).
Damping is set at the factory for the average solo rider under normal riding conditions. The rider
may make adjustments to compensate for individual riding styles and varying road conditions.
Evaluating and changing the rebound and compression damping is a very subjective process with
many variables and should be approached carefully.
Changes in Load
Changes in the load carried requires changes in the preload settings. Carrying less weight than
was used for setting up the suspension requires decreasing the amount of preload. Increasing the
load carried requires adding more preload.
Front Fork: XR 1200X
Adjust both forks equally. Improper fork adjustment can
lead to loss of control, which could result in death or
Compression and rebound adjusting valves may be
damaged if too much force is used at either end of the
adjustment range. (00237a)
Spring Preload
1. See Spring Preload Adjuster: XR 1200X. With a hex key, turn the preload adjuster
counterclockwise until it stops. This is the minimum preload setting.
2. Calculate the total load and turn the adjuster clockwise to specification. Refer to
Recommended Fork Preload: XR 1200X.
Rebound Damping
1. See Fork Rebound and Compression Damping Adjusters: XR 1200X. Turn the
rebound damping adjuster (1) clockwise H (hard) until it stops. This is the maximum rebound
setting.
2. Turn adjuster counterclockwise S (soft) to specification. Refer to Recommended Fork
Rebound and Compression Damping Adjustment: XR 1200X.
Compression Damping
1. See Fork Rebound and Compression Damping Adjusters: XR 1200X. Turn the
compression damping adjuster (2) clockwise H (hard) until it stops. This is the maximum
compression setting.
2. Turn the adjuster counterclockwise S (soft) to specification. Refer to Recommended Fork
Rebound and Compression Damping Adjustment: XR 1200X.
Spring Preload Adjuster: XR 1200X
Recommended Fork Preload: XR 1200X
LOAD* TURNS**
FROM
MINIMUM
Less than 165 lb 75.0 kg 04
165195 lb 75.089.0 kg 46
195225 lb 89.0102.0 kg 68
225255 lb 102.0116.0 kg 810
255 lb 116.0 kg to maximum added weight More
allowed. Refer to Weights: XL 1200 than 10
Models and XR 1200X.
*Add the weight of the rider, passenger, riding gear,
accessories, and cargo.
**Turns are clockwise turns in from minimum.
To increase preload, turn the adjuster clockwise.
To decrease preload, turn the adjuster
counterclockwise.
1. Rebound damping adjuster
2. Compression damping adjuster
Fork Rebound and Compression Damping
Adjusters: XR 1200X
Recommended Fork Rebound and Compression Damping Adjustment: XR 1200X
DAMPING* NOMINAL (FROM MAXIMUM)
Rebound (REB) 3
Compression (COM) 5
*Values shown are counterclockwise turns out from
maximum. Rotate adjuster clockwise to increase
damping or counterclockwise to decrease damping.
Shock Absorber Preload: All Models
Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)
Do not turn the shock absorber adjustment collar
clockwise beyond adjustment setting 5. Doing so may
result in equipment damage. (00166b)
NOTES:
Five Position Shocks: See Shock Preload Cam Positions (typical). Do not turn the
preload cam past position five (5) to position one (1) or from position one (1) to position five
(5).
Three Position Shocks: Do not turn the preload cam past position three to position one or
from position one (1) to position three.
XL Models: See Shock Absorber Preload Adjustment: XL Models. Using SHOCK
ADJUSTMENT SPANNER 9444882B , turn the adjustment cam to specification.
Five Position Shocks: Refer to Recommended Shock Preload: Five Position.
Three Position Shocks: Refer to Recommended Shock Preload: Three Position.
XR 1200X: See Shock Absorber Preload Adjustment: XR 1200X. Use the spanner wrench
with extension handle from the tool kit to turn the adjustment cam to specification. Refer to
Recommended Shock Preload: Five Position.
Shock Absorber Preload Adjustment: XL Models
Shock Absorber Preload Adjustment: XR 1200X
Shock Preload Cam Positions (typical)
XL 883L/N, XL1200N/X/V and certain XL1200CP models are configured for solo operation. If you
choose to add a passenger and/or cargo to the vehicle, the ride quality may be compromised. See
a HarleyDavidson dealer for twoup seats, passenger pegs and suspension options.
Recommended Shock Preload: Five Position
LOAD* POSITION**
165195 lb 75.089.0 kg 2
195225 lb 89.0102.0 kg 3
225255 lb 102.0116.0 kg 4
255 lb 116.0 kg to maximum added weight 5
allowed. Refer to Weights: XL 883
Models and Weights: XL 1200 Models
and XR 1200X.
* Add the weight of the rider, passenger, riding gear,
** See Shock Preload Cam Positions (typical).
Recommended Shock Preload: Three Position
LOAD* POSITION
165225 lb 75.0102.0 kg 2
225 lb 102.0 kg to maximum added weight 3
allowed. Refer to Weights: XL 883 Models
and Weights: XL 1200 Models and XR
1200X.
* Add the weight of the rider, passenger, riding gear,
Maximum Added Weight Allowed: Sportster Models
MODEL MAX LOAD
lb kg
XL 883L 437 198.2
XL 883N 435 197.3
XL 883R 427 193.7
XL 1200C 418 198.9
XL 1200N 438 198.7
XL 1200X 433 196.4
XL 1200V 445 201.8
XR 1200X 427 193.7
Shock Absorber Rebound and Compression: XR 1200X
Adjust both shock absorbers equally. Improper adjustment
can adversely affect stability and handling, which could
result in death or serious injury. (00036b)
Compression and rebound adjusting valves may be
damaged if too much force is used at either end of the
adjustment range. (00237a)
Shock Absorber Rebound Damping Adjustment
1. See Rebound Damping Adjuster: XR 1200X. Turn the rebound adjuster in the direction
of the embossed H (hard) until it stops. This is the maximum rebound damping setting.
2. Turn the rebound adjuster toward the embossed S (soft) the recommended number of
clicks. Refer to Recommended Rear Shock Rebound and Compression Damping:
XR 1200X.
Shock Absorber Compression Damping Adjustment
1. See Compresson Damping Adjuster: XR 1200X. Using fingers, turn the compression
adjuster clockwise H (hard) until it stops. This is the maximum compression damping
setting.
2. Turn the compression adjuster counterclockwise (H to S) (hard to soft) the recommended
number of clicks. Refer to Recommended Rear Shock Rebound and Compression
Damping: XR 1200X.
Rebound Damping Adjuster: XR 1200X
Compresson Damping Adjuster: XR 1200X
Recommended Rear Shock Rebound and Compression Damping: XR 1200X
DAMPING CLICKS FROM MAX
(H to S)
Rebound (REB) 5
Compression (COMP) 7
Compression (COMP) 7
Suspension Tuning: XR 1200X
After the preload and damping have been set to the recommended settings, additional
adjustments can be made to enhance the comfort, control and handling characteristics of the
motorcycle. These adjustments may be based on personal riding style, desired ride quality, and
varying road conditions.
1. Set the front forks and shock absorbers to the recommended settings. Properly inflate the
tires.
2. Determine the ride quality of the motorcycle. Ride the motorcycle on a familiar road with a
variety of bumps and turns. Ride over different surfaces at varying speeds. If the suspension
is set properly, the vehicle suspension will feel controlled and comfortable.
3. Adjust the rebound and compression damping according to the motorcycle behavior
experienced during the ride. Refer to Suspension Damping Adjustment Guidelines:
XR 1200X.
4. After adjusting the suspension, ride the motorcycle again to check for comfort and response.
NOTE:
When tuning the suspension, make all adjustments in small increments. Radical setting changes
may overshoot the best adjustment setting.
Suspension Damping Adjustment Guidelines: XR 1200X
MOTORCYCLE BEHAVIOR SUGGESTED REMEDY
Soft or unsettled feeling around corners or after bumps Increase rebound damping.
Leaping feeling or topping after large bumps Increase rebound damping.
Harsh/sharp feedback over bumps Decrease rebound damping.
Feels like motorcycle drops down over chatter bumps Decrease rebound damping.
Excessive bottoming through potholes Increase compression damping.
Excessive dive when applying front brake Increase compression damping (forks).
Hard feeling or inadequate absorption over bumps Decrease compression damping.
Feels excessively stiff or busy around corners Decrease compression damping.
SideMounted License Plate
See SideMounted License Plate Assembly. Some models are equipped with a sidemounted
license plate assembly. The license plate must be in the extended position during operation. Due
to local regulations, this feature may not be available in all locations.
The sidemounted license plate assembly includes an LED lamp module. If the LED lamp fails,
see a HarleyDavidson dealer for assembly replacement.
SideMounted License Plate Assembly
HarleyDavidson Smart Security System
HarleyDavidson Smart Security System
Components
The HarleyDavidson Smart Security System (HDSSS) consists of a HandsFree Security
Module (HFSM) and a handsfree antenna mounted on the motorcycle, and a handsfree fob
carried by the rider/passenger.
After parking the motorcycle, turn the ignition key to OFF and the Smart Security System will
automatically arm within five seconds. While armed, the starter and ignition are disabled and the
rider may leave the motorcycle knowing that the module will activate an alarm if someone tampers
with the ignition or attempts to move the motorcycle.
If the fob is present, the module will automatically disarm when the ignition key is turned to
IGNITION or ACC.
NOTE:
Do not relocate the module or the antenna on the motorcycle.
Options
Several options are available for the HarleyDavidson Smart Security System from the Harley
Davidson Genuine Motor Accessories and Motor Parts catalog. Options include:
Smart Siren II.
Security Pager Receiver II.
Replacement Fobs.
See a HarleyDavidson dealer for details.
FCC Regulations
FCC ID: L2C0027TR IC ID: 3432A0027TR
FCC ID: L2C0028TR IC ID: 3432A0028TR
This device complies with Part 15 of the FCC Rules and with RSS210 of Industry Canada rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
NOTE:
Changes or modifications not expressively approved by the party responsible for compliance
could void the user's authority to operate the equipment.
The term "IC:" before the radio certification number only signifies that Industry Canada technical
specifications were met.
Security System Fob
Fob Assignment
See Fob: Smart Security System. Key fobs are electronically assigned to the HarleyDavidson
Smart Security System by a HarleyDavidson dealer so that the motorcycle can recognize a fob's
unique signal. Only two fobs can be assigned at any one time.
Replacement fobs can be purchased from a dealership but can only be assigned to the
motorcycle by a trained HarleyDavidson technician.
NOTES:
The reusable label found on the fob packaging lists the serial number of the fob. For
reference, affix the label to a blank "NOTES" page in this Owner's Manual.
The serial number of the fob is also found on the inside of the fob. See Fob Battery.
The module will arm only if the fob has been assigned by a HarleyDavidson dealer and a
Personal Identification Number (PIN) has been entered in the system. The PIN should be
recorded on the Personal Information page in the front of this Owner's Manual and on the
removable wallet card.
Should the rider misplace the fob or if the fob fails, the rider can refer to the wallet card and
use the PIN to manually disarm the system. Refer to Arming and Disarming and Fob
Battery.
The PIN can easily be changed by the rider at any time. Refer to Personal Identification
Number (PIN).
Riding with a Fob
Always carry the fob when riding, loading, fueling, moving, parking or servicing the
motorcycle. Carry the fob in a convenient pocket.
Do not leave the fob attached to the handlebars or store the fob in a luggage compartment.
Unintentionally leaving the fob with the motorcycle when it is parked prevents the system
from activating the alarm.
Do not ride with the fob stored in a metal case or with the fob closer than 3.0 in 76 mm to a
cell phone, PDA, display or other electronic device. Any electromagnetic interference may
prevent the fob from disarming the system.
For added security, always lock the fork and remove the key when parked. If the fob is
within range and the motorcycle is unlocked, tampering with the motorcycle will not activate
the alarm.
Fob: Smart Security System
Personal Identification Number (PIN)
The Personal Identification Number (PIN) is a number that can be used to disarm the Harley
Davidson Smart Security System in case an assigned fob is misplaced, fails or if the fob cannot
communicate with the motorcycle because of electromagnetic interference.
A PIN is a fivedigit number (19, no zeros).
Changing the PIN
To maintain security, the rider can change the PIN at any time. Refer to Changing the PIN.
Changing the PIN
STEP ACTION WAIT FOR CONFIRMATION NOTES

NO.
1 Select a 5digit (1 thru 9) PIN
and record on the wallet card
from Owner's Manual.
2 With an assigned fob present,
turn IGN key IGNITIONOFF
IGNITIONOFFIGNITION.
3 Press left turn signal switch 3
times.
4 Press right turn signal switch Turn signals will flash 3 times. See Odometer
1 time and release. Current PIN will appear in Windows PIN.
odometer. The first digit will be
flashing.
5 Enter first digit (a) of new PIN
by pressing left turn signal
switch a times.
6 Press right turn signal switch The new digit (a) will replace the
1 time and release. current in odometer window.
7 Enter second digit (b) of new
PIN by pressing left turn
signal switch b times.
8 Press right turn signal switch The new digit (b) will replace the
1 time and release. current in odometer window.
9 Enter third digit (c) of new PIN
switch c times.
10 Press right turn switch 1 time The new digit (c) will replace the
and release. current in odometer window.
11 Enter fourth digit (d) of new
PIN by pressing left turn
signal switch d times.
12 Press right turn switch 1 time The new digit (d) will replace the
13 Enter fifth digit (e) of new PIN
switch e times.
14 Press right turn switch 1 time The new digit (e) will replace the
15 Before the module rearms, The odometer will return to Turning the ignition
turn the ignition key to OFF. mileage. key to OFF stores the
new PIN in the
module.
1. Current PIN (example) on PIN Change
2. PIN Disarm
Odometer Windows PIN
Security Status Indicator
See Instruments: XL Models. The security system lamp in the speedometer face indicates the
status of the HarleyDavidson Smart Security System.
Armed: A lamp that blinks approximately every 3 seconds indicates that the system is
armed.
Disarmed: After the system disarms and the ignition is on, the lamp will remain illuminated
for approximately four seconds and then turn off.
Service: A lamp that remains illuminated longer than four seconds while the system is
disarmed indicates that service of the module is required.
Arming and Disarming
Arming
When the motorcycle is parked and the ignition key is turned to OFF, the HarleyDavidson Smart
Security System arms automatically within five seconds if no motion is detected. Even when the
fob is present, the system will arm.
On arming, the turn signals will flash twice and the optional siren will chirp twice. While armed, the
key icon in the speedometer face will flash every three seconds.
NOTE:
International Models: The HFSM must be in the Chirp Mode for the siren to chirp on arming or
on disarming. See Siren Chirp Mode (Confirmation).
Disarming
Once disarmed, the rider may ride or move the motorcycle for parking, storage or service without
setting off the alarm.
Fob: An armed Smart Security System is automatically disarmed when the ignition key is turned
to IGNITION with the fob present.
When the module disarms, the optional siren will chirp once and the key icon will illuminate for a
solid four seconds and then turn off.
NOTE:
Any motion, like lifting the motorcycle up off of its jiffy stand, or turning the ignition key to
IGNITION and the module will electronically search for the presence of the fob. If the fob is
present, the system disarms.
Personal Identification Number (PIN): If the fob is misplaced or if the present fob fails to
communicate with the module, the system can be disarmed with the Personal Identification
Number (PIN).
Disarming with a PIN
Do not turn handlebars, straddle seat or lift motorcycle off the jiffy stand. During a PIN disarm, if
the Smart Security System detects motorcycle motion the system will activate the alarm.
Entering a PIN to Disarm HarleyDavidson Smart Security System
NO.
1 If necessary, verify the Should be recorded on
current 5digit PIN. wallet card.
2 Turn ignition key to
IGNITION.
3 Quickly (within 2 seconds of Key icon flashes at fast rate. In See Odometer
turning ignition key) hold both the odometer window, a flashing Windows PIN. Five
turn signal switches in until dash will be followed by four dashes will appear in the
confirmation. more dashes. odometer window.
4 Enter first digit (a) in the PIN The first digit (a) in the
by pressing left turn switch a odometer will be the first digit in
times. the PIN.
5 Press right turn switch 1 The first digit is stored and the Serves as enter key.
time. dash will flash.
6 Enter second digit (b) in the The second digit (b) in the
PIN by pressing left turn odometer will be the second
switch b times. digit in the PIN.
7 Press right turn switch 1 The second digit is stored and Serves as enter key.
time. the next dash will flash.
8 Enter third digit (c) in the PIN The third digit (c) in the
by pressing left turn switch c odometer will be the third digit in
times. the PIN.
9 Press right turn switch 1 The third digit is stored and the Serves as enter key.
time. next dash will flash.
10 Enter fourth digit (d) in the The fourth digit (d) in the
PIN by pressing left turn odometer will be the fourth digit
switch d times. in the PIN.
11 Press right turn switch 1 The fourth digit is stored and the Serves as enter key.
time. next dash will flash.
12 Enter fifth digit (e) in the PIN The fifth digit (e) in the
by pressing left turn switch e odometer will be the fifth digit in
times. the PIN.
13 Press right turn switch 1 The fifth digit is stored. The key Smart Security System is
time. icon stops blinking. disarmed.
NOTES:
At any time during a PIN disarm, if the fob is brought within range of the motorcycle, the
Smart Security System will disarm when the module receives the coded signal from the fob.
If a mistake is made while entering PIN, wait two minutes before another disarming attempt.
The Smart Security System will remain disarmed until the ignition key is turned to OFF.
Arming with Hazard Warning 4Way Flashers On
If it should be necessary to leave a motorcycle parked along side a roadway, the hazard warning
fourway flashers can be turned ON and the Smart Security System armed.
1. Turn ignition key to IGNITION.
2. Simultaneously press both left and right turn signal switches to turn the fourway flashers
ON.
3. Turn the ignition key to OFF to arm the Smart Security System.
To turn hazard warning flashers OFF, turn the ignition key to IGNITION and simultaneously press
the left and right turn signal switches.
Alarm
Warnings
Once armed, if the motorcycle is moved or lifted up off of its jiffy stand or if the ignition key is
turned to IGNITION and the fob is not present, the alarm will warn the operator with three
alternate flashes of the turn signals and a chirp of the optional siren.
Within four seconds, if the motorcycle is back on its jiffy stand and no further motion is detected
and/or the ignition key is turned to OFF, the module will remain armed without activating the
alarm.
If the motorcycle motion continues or the ignition key is not turned back to OFF, the module will
issue a second warning four seconds after the first.
NOTE:
During warnings and alarms, the starter motor and the ignition circuits are disabled.
The Alarm
If the Smart Security System is still detecting motion and/or if the ignition key has not been turned
back to OFF after a second warning, the system will activate the alarm.
When activated, the Smart Security System will:
Alternately flash the four turn signals.
Sound the optional siren.
Duration: The alarm will stop within 30 seconds and if no motion is detected, the alarm will not
restart.
However, if motorcycle motion continues the system will repeat the 30 second alarm and recheck
for motion. The alarm will repeat this 30 second alarm cycle for five minutes (10 cycles) or until
the alarm is deactivated.
NOTE:
The alarm will also activate the LED, vibration or audible modes of a HarleyDavidson Security
Pager. A pager can operate either in silent or in combination with an optional Smart Siren. The
range of a pager can be up to 0.5 mi 0.8 km . See a HarleyDavidson dealer for details.
Deactivate the Alarm
Key Fob: Bring the fob to the motorcycle. After the module identifies that the fob is present, the
system will terminate the alarm.
Siren Chirp Mode (Confirmation)
Chirp Mode
In chirp mode, the siren sounds two chirps when arming, and a single chirp when disarming.
Chirpless Mode
In chirpless mode, the siren does not chirp on arming or disarming.
The siren will still provide warning chirps and sound the alarm if the motorcycle is moved or the
ignition switch is turned on without the fob present.
Switching Modes
Perform the following to switch between chirp and chirpless modes.
1. With the fob present, turn the ignition switch ON.
2. When the security lamp turns off, turn the ignition switch OFF.
3. When the security lamp turns off (but before the turn signals flash twice), immediately turn
the ignition switch ON.
4. When the security lamp turns off, immediately turn the ignition switch OFF.
6. When the security lamp turns off, immediately turn the ignition switch OFF.
Transport Mode
It is possible to arm the security system without enabling the motion detector for one ignition
cycle. This allows the vehicle to be picked up and moved in an armed state, however, any attempt
to start the engine when the key fob is not within range will trigger the alarm.
To Enter Transport Mode
1. Turn the ignition switch to IGN.
2. Set the engine stop switch to OFF.
3. With an assigned fob within range, turn the ignition switch from IGN to ACC.
4. Simultaneously press both the left and the right turn signal switches. This must be done
within five seconds of turning the ignition switch to ACC.
5. After the turn signals flash once, turn the ignition switch to OFF and the module is armed.
6. Confirmation: Turn signal blinks three times when armed for one ignition cycle.
To Exit Transport Mode
Return the system to normal operation:
With the fob present, turn the ignition switch to IGN to disarm the system. To cancel the transport
mode, set the engine stop switch to RUN.
Storage and Service Departments
LongTerm Parking
To maintain arming, store the fob beyond the range of the antenna more than 20 ft 6 m away. If
the motorcycle is to be moved while parked, have the fob present.
If the motorcycle will not be operated for several months, such as during the winter season, refer
to Motorcycle Storage.
Service Departments
When the motorcycle is to be left at a HarleyDavidson dealer, there are two options:
1. Leave an assigned fob with the dealer.
2. To maintain possession of the fob, ask the dealer to disable the system for service (service
mode) before leaving the dealership.
Fob Battery
Replacing the Battery
Replace the fob battery every year.
1. See Fob Battery. Slowly turn a thin blade in the thumbnail slot (1) on the side of the fob to
separate the two halves.
2. Remove the battery (2) and discard.
NOTE:
Dispose of the old battery in accordance with local regulations.
3. Install a new battery (Panasonic 2032 or equivalent) with the positive (+) side down.
4. Align the two halves of the fob and snap together.
1. Thumbnail slot
2. Battery
3. Fob serial number
Fob Battery
Disconnecting Power
Siren Equipped Models
When disconnecting the battery or removing the main fuse, perform the following steps to prevent
the optional siren from sounding.
1. Verify that the fob is present.
2. Turn the ignition switch to IGNITION.
3. Pull the main fuse from its holder or disconnect the battery.
Troubleshooting
Security System Indicator
If the system indicator lamp stays illuminated while riding, see a HarleyDavidson dealer.
Fob
If the Smart Security System continues to actuate warnings and alarms with the fob present, one
of the following can be the cause:
1. Electromagnetic Interference: Other electronic devices, power lines, or other
electromagnetic sources can cause the Smart Security System to operate inconsistently.
a. Verify that the fob is not in a metal enclosure or within 3.0 in 76 mm of any other
electronic devices.
b. Place the fob on the seat and turn the ignition to IGN. After the system disarms, return
the fob to a convenient location.
c. Move motorcycle at least 15 ft 5 m from the spot of interference.
d. Use the PIN to disarm the system.
NOTE:
Leaving a fob next to a computer monitor can run down the battery.
2. Discharged Fob Battery: Use the PIN to disarm the system. Replace the battery. Refer to
Fob Battery.
3. A Damaged Fob: Use the PIN to disarm the motorcycle. Replacement fobs are available for
purchase from a HarleyDavidson dealer.
Siren
If the siren does not chirp two or three times on a valid arming command from the security
module, the siren is either in the Chirpless Mode, not connected, not working, or the siren
wiring was opened or shorted while the siren was disarmed.
If the siren is armed and the internal siren battery is dead, shorted, disconnected, or has
been charging for a period longer than 24 hours, the siren will respond with three chirps on
arming instead of two.
The internal siren battery may not charge if the vehicle's battery is less than 12.5 volts.
If the siren enters the selfdriven mode where it is powered from the siren's internal 9 volt
battery, the turn signal lamps may or may not alternately flash. If the security module
activates the siren, the turn signal lamps will alternately flash. If the siren has been armed
and a security event occurs, and the siren is in selfdriven mode, the siren will alarm for 20
30 seconds and then turn off for 510 seconds. This alarm cycle will be repeated ten times if
the siren is in the selfdriven mode.
Operation
Operating Recommendations
Motorcycles are different from other vehicles. They
operate, steer, handle and brake differently. Unskilled or
improper use could result in loss of control, death or
Take a rider training course.
Read Owner's Manual before riding, adding accessories or servicing.
Wear a helmet, eye protection and protective clothing.
Never tow a trailer.
Do not run the engine at extremely high RPM with clutch
disengaged or transmission in neutral. Running an engine
at high RPM can result in engine damage. (00177a)
Do not exceed the maximum safe RPM specified below
under any conditions. Exceeding the maximum safe
engine RPM can result in equipment damage. (00248a)
The maximum recommended safe engine speed is 6000 rpm for XL models and 6800 rpm
for the XR 1200X.
Do not idle engine unnecessarily for more than a few minutes with motorcycle standing still.
If motorcycle will not be ridden for a period of two weeks or more with security system armed, it is
recommended to connect a 750mA SUPERSMART BATTERY TENDER 9465498B to maintain
battery charge. If security system will not be armed, it is recommended that the 30 A maxifuse be
removed. See Fuses and Relays.
Aircooled engines require air movement over the
cylinders and heads to maintain proper operating
temperature. Extended periods of idling or parade duty can
overheat the engine, resulting in serious engine damage.
(00178a)
An engine running long distances at high speed must be given closer than ordinary attention to
avoid overheating and possible engine damage.
NOTE:
Have the engine checked regularly and keep it well tuned.
This applies particularly to a motorcycle equipped with windshield and fairing.
When riding on wet roads, brake efficiency and traction are
greatly reduced. Failure to use care when braking,
accelerating or turning on wet roads can cause loss of
(00041a)
NOTE:
When descending upon a long, steep grade, downshift and use engine compression together with
intermittent application of both brakes to slow the motorcycle.
Continuous use of brake causes overheating and reduced
efficiency, which could result in death or serious injury.
(00042a)
Do not tow a disabled motorcycle. Towing can adversely
affect stability and handling, which could result in death or
Breakin Riding Rules
The First 500 Miles (800 Kilometers)
The sound design, quality materials, and workmanship that are built into your new Harley
Davidson will give you optimum performance right from the start.
To allow your engine to wearin its critical parts, we recommend that you observe the riding rules
provided below for the first 500 mi 800 km .
1. During the first 50 mi 80 km of riding, keep the engine speed below 3000 rpm in any gear.
Do not lug the engine by running or accelerating at very low rpm, or by running at high rpm
longer than needed for shifting or passing.
2. Up to 500 mi 800 km , vary the engine speed and avoid operating at any steady engine
speed for long periods. Engine speed up to 3500 rpm in any gear is permissible.
3. Drive slowly and avoid fast starts at wide open throttle until the engine has warmed up.
4. Avoid lugging the engine by not running the engine at very low speeds in higher gears.
5. Avoid hard braking. Breakin new brakes with moderate use for the first 100 mi 160 km .
PreRiding Checklist
Read the CONTROLS AND INDICATORS section before
riding your motorcycle. Failure to understand the
operation of the motorcycle could result in death or
Before riding your motorcycle at any time, make a general inspection to be sure it is in safe riding
condition.
Stop the engine when refueling or servicing 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)
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
1. Verify fuel is present in tank and add fuel if required.
2. Adjust mirrors to proper riding positions.
3. Check the oil level. Add oil if necessary.
4. Check controls to make sure they operate properly. Operate the front and rear brakes,
throttle, clutch and shifter. All controls should operate freely without binding.
5. Check steering for proper operation by turning the handlebars through the full operating
range. Handlebars should turn smoothly without binding.
6. Check tire condition, pressure and motorcycle loading. Incorrect pressure and excessive
loading can lead to tire or wheel failure, and can affect handling and stability. Refer to Tires:
2012 Sportster Models for correct inflation pressure.
Be sure headlamp, tail and stop lamp and turn signals are
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
7. Check all electrical equipment and switches including the headlamp, stop lamp, turn signals
and horn for proper operation.
8. Check for any fuel, oil or hydraulic fluid leaks.
9. Visually check drive belt for wear or damage.
10. Service your motorcycle as necessary.
Starting the Engine
Shift transmission to neutral before starting engine to
prevent accidental movement, which could result in death
or serious injury. (00044a)
The engine should be allowed to run slowly for 1530
seconds. This will allow the engine to warm up and let oil
reach all surfaces needing lubrication. Failure to comply
can result in engine damage. (00563b)
NOTE:
Do not open the throttle before starting the engine.
1. Turn ignition key to IGNITION.
2. See Handlebar Controls. Switch the OFF/RUN switch to the RUN position.
NOTE:
The engine lamp will light for approximately 4 seconds. You will hear the fuel pump purr for
approximately 2 seconds as it operates to fill the fuel lines with gasoline.
3. Verify transmission is in NEUTRAL position by observing the lit green neutral indicator lamp
on the dash panel and verify neutral position by rolling motorcycle forward and rearward.
4. Squeeze the clutch lever against the handlebar.
5. Press the START button.
6. When the engine has started, you can operate your motorcycle as you normally would after
raising the jiffy stand.
1. Engine OFF/RUN switch
2. Engine START switch
Right Handlebar Controls
Shifting Gears
Shifting while Stopped, Engine Off
Squeeze in the clutch lever to fully disengage the clutch. Gears may not engage because the
transmission shafts are not turning and shifter components are not lined up. Rock the motorcycle
backward and forward while lightly pressing on the shift lever.
Starting from a Stop
The clutch must be fully disengaged before attempting a
gear shift. Failure to fully disengage the clutch can result
in equipment damage. (00182a)
NOTE:
Always start the engine with the transmission in neutral. Always start forward motion in first gear.
1. With the engine running and the jiffy stand retracted, pull the clutch hand lever in against the
handlebar grip to fully disengage the clutch.
2. Press the gear shift lever down to end of its travel and release. The transmission is now in
first gear.
3. Ease out the clutch lever and at the same time, gradually open the throttle.
Upshift (Acceleration)
1. See Upshift Sequence: Sportster Models. Close the throttle.
2. Disengage the clutch (pull the clutch lever in).
3. Lift the gear shift lever up to the end of its travel and release.
4. Ease out the clutch lever and gradually open the throttle.
5. Repeat the previous steps to engage remaining gears.
NOTES:
Disengage the clutch completely before each gear change.
Partially open the throttle so the engine does not drag when the clutch lever is released.
Upshift Sequence: Sportster Models
Downshift (Deceleration)
Do not downshift at speeds higher than those listed.
Shifting to lower gears when speed is too high can cause
the rear wheel to lose traction and lead to loss of vehicle
(00045b)
See Downshift Sequence: Sportster Models. When engine speed decreases, as when
climbing a hill or slowing for a turn, shift to the next lower gear. Refer to Downshift
(Deceleration) Road Speeds*.
Downshift (Deceleration) Road Speeds*
GEAR CHANGE mph km/h

Fifth to fourth 40 65
Fourth to third 30 50
Third to second 20 30
Second to first 10 15
* The listed speeds are recommendations. Individual
riding styles may determine gear change road speeds.
NOTE:
The shifting points shown in the table are recommendations. Vehicle owners may determine that
their own individual shifting patterns may differ from those stated and are additionally appropriate
for individual riding styles.
1. Close the throttle.
2. Disengage the clutch (pull the clutch lever in).
3. Press the gear shift lever down to the end of its travel and release.
4. Ease out the clutch lever and gradually open the throttle.
5. Repeat the previous steps to engage remaining gears.
NOTES:
Disengage the clutch completely before each gear change.
Partially open the throttle so the engine does not drag when clutch lever is released).
Shift to neutral before stopping engine. Shifting
mechanism can be damaged by shifting gears while
engine is stopped. (00183a)
The gear shifter mechanism permits shifting the transmission to neutral from either first or second
gear.
Downshift Sequence: Sportster Models
Stopping the Engine
1. Stop the engine by turning the engine OFF/RUN switch on the right handlebar to OFF.
2. Turn the ignition switch to OFF. If the engine should be stalled or stopped in any way, turn
the ignition switch to OFF at once to prevent battery discharge.
Maintenance and Lubrication
Safe Operating Maintenance
Good maintenance creates a safe motorcycle. A careful check of certain equipment must be
made after periods of storage. Also, frequently inspect the motorcycle between the regular service
intervals to determine if additional maintenance is necessary.
Check the following items:
1. Tires for correct pressure, abrasions or cuts.
2. Belt and primary chain for proper tension, wear or damage.
3. Brakes, steering and throttle for responsiveness and freedom from binding.
4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads
and discs for wear.
5. Cables for fraying or crimping and free operation.
6. Engine oil and primary chaincase/transmission fluid levels.
7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.
Breakin Maintenance
NOTE:
The performance of new motorcycle initial service is required to keep your new motorcycle
warranty in force and for proper emissions system operation.
After a new motorcycle has been ridden its first 1000 mi 1600 km , it should be taken to an
authorized HarleyDavidson dealer for initial service operations. Refer to Regular Service
Intervals: 2012 Sportster Models.
Engine Lubrication
Prolonged or repeated contact with used motor oil may be
harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b)
If swallowed, do not induce vomiting. Contact a physician
immediately. In case of contact with eyes, immediately
flush with water. Contact a physician if irritation persists.
(00357c)
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)
Engine oil is a major factor in the performance and service life of the engine. Always use the
proper grade of oil for the lowest temperature expected before the next scheduled oil change.
Refer to Recommended Engine Oils.
This motorcycle was originally equipped with Genuine HD 360 MultiGrade 20W50 engine oil. H
D 360 is the preferred oil under normal operating conditions. If operation under extreme cold or
heat are expected, refer to Recommended Engine Oils for alternative choices.
If necessary and HD 360 is not available, add oil certified for diesel engines. Acceptable
designations include: CH4, CI4 and CJ4. The preferred viscosities, in descending order are:
20W50, 15W40 and 10W40.
At the first opportunity, see an authorized dealer to change back to 100 percent HarleyDavidson
oil.
Recommended Engine Oils
TYPE VISCOSITY RATING LOWEST COLD WEATHER STARTS

AMBIENT BELOW 50 °F (10 °C)
TEMPERATURE
Screamin' Eagle SYN3 SAE HD 360 Above 30 °F 1 Excellent
Synthetic 20W50 °C
Motorcycle Lubricant
Genuine HD 360 Multi SAE HD 360 Above 40 °F 4 Good
grade 20W50 °C
Genuine HD 360 Regular SAE 50 HD 360 Above 60 °F 16 Poor
Heavy °C
Genuine HD 360 Extra SAE 60 HD 360 Above 80 °F 27 Poor
Heavy °C
Multigrade SAE SH, CH Below 40 °F 4 Excellent
10W40 4, °C
(oil certified for use in
diesel engines) CI4,
CJ4
Checking and Adding Oil
Removing and Replacing Oil Filler Cap
1. Park the motorcycle on level ground on the jiffy stand.
2. See Filler Cap/Dipstick Location. Remove the filler cap from the oil tank.
a. Press straight down on the filler cap and release. The cap will pop up.
b. Pull up on the filler cap while turning counterclockwise onequarter turn as if removing
the filler cap.
3. Wipe the dipstick clean.
NOTE:
See Filler Cap/Dipstick Slots. Insert the dipstick with the wide slot (1) and the narrow slot
(2) matched to the wide tab and narrow tab inside the oil tank filler neck.
4. Insert the dipstick into the tank.
a. Turn the filler cap clockwise onequarter turn as if screwing the filler cap into tank.
When the filler cap stops turning, it is seated.
b. Press down on the filler cap until it snaps in place, flush with the top of the oil tank
cover.
Filler Cap/Dipstick Location
1. Wide slot
2. Narrow slot
Filler Cap/Dipstick Slots
Oil Level Cold Check
NOTES:
Check engine oil level at each complete fuel refill.
An accurate engine oil check can only be made with the engine at operating temperature
(Hot Check).
2. Remove the filler cap and wipe the dipstick clean. Install the oil filler cap in tank.
3. Remove oil filler cap again and visually check for oil in the tank.
4. If oil is not visible in the tank, install the filler cap.
NOTE:
If the oil pressure lamp stays lit after starting engine, immediately shut the engine off.
5. Start and idle the engine for 30 seconds. Stop the engine.
6. Remove oil filler cap and visually check for oil in the tank.
Do not overfill oil. Doing so can result in oil carryover to
the air cleaner leading to equipment damage and/or
equipment malfunction. (00190b)
NOTE:
Use only recommended oil. Recommended viscosity depends upon ambient temperature. Refer
to Recommended Engine Oils.
7. If there is no oil visible in the tank, add oil until it is present on the bottom of the dipstick.
8. When oil is present on the bottom of the dipstick, perform a hot check.
Oil Level Hot Check
1. Run the engine until the engine oil is at operating temperature.
2. Idle the motorcycle on the jiffy stand for one to two minutes. Turn the engine off.
4. Remove the filler cap. Wipe the dipstick clean and install the filler cap in the tank.
Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)
NOTES:
Use only recommended oil. Recommended viscosity depends upon ambient temperature.
Refer to Recommended Engine Oils.
Do not overfill the oil tank. The oil tank has a builtin pressure relief valve. If the oil tank is
overfilled, excessive pressure is created in the oil tank. The pressure relief valve will open to
relieve the pressure and prevent damage to the oil tank. Excessive oil due to overfilling will
also be forced out the pressure relief valve when it opens.
5. See Filler Cap/Dipstick. Remove the filler cap and check the hot oil level on the dipstick.
a. Below the Lower Mark: Add only enough oil until the level reads between the upper
and lower marks.
b. Between the Upper and Lower Marks: It is safe to operate the motorcycle.
c. At (or above) the Upper Mark: Drain the oil until the level reads between the upper
and lower marks.
6. Install the filler cap.
7. If oil was added, remove the filler cap and verify the engine oil level in the oil tank. Do not fill
oil tank to a level above upper mark on the dipstick. Install the filler cap.
1. Lower mark
2. Upper mark (full)
Filler Cap/Dipstick
Changing Oil and Filter
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)
Refer to Regular Service Intervals: 2012 Sportster Models. Completely drain oil tank of
used oil at scheduled service intervals. Refill with fresh oil.
NOTES:
Change oil at specified intervals in normal service at warm or moderate temperatures. Refer
to Regular Service Intervals: 2012 Sportster Models.
Change engine oil at shorter intervals in cold weather or in severe operating conditions. See
Winter Lubrication.
Change engine oil at shorter intervals if ridden extremely hard, used in competition, or
driven on dusty roads.
Always change oil filter when changing engine oil.
Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)
Draining Oil Tank
1. Run engine until engine oil has reached normal operating temperature.
2. Remove oil filler cap/dipstick from oil tank. Oil will drain faster when filler cap/dipstick is
removed.
3. See Oil Tank Drain Hose. Place a suitable container directly under the drain hose (1) at
the bottom rear of the engine crankcase. The container must be able to hold approximately
3.0 qt 2.8 L .
4. Loosen worm drive clamp (2). Pull drain plug (3) from end of drain hose. Completely drain
engine oil from oil tank. Draining engine crankcase only if needed.
5. Install drain plug into end of drain hose. Tighten worm drive clamp to610 inlbs (0.71.1
Nm).
1. Oil tank drain hose
2. Worm drive clamp
3. Drain plug
Oil Tank Drain Hose
Removing Oil Filter
1. Place a drain pan beneath front of engine crankcase.
Use HarleyDavidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position
sensor and/or sensor cable. (00192b)
2. See Oil Filter Wrenches and Oil Filter. Remove oil filter using HARLEYDAVIDSON OIL
FILTER WRENCH HD42311 or HARLEYDAVIDSON OIL FILTER WRENCH HD44067A .
Turn oil filter counterclockwise to remove from filter mount.
3. Drain oil filter into drain pan. Discard oil filter.
4. Clean any oil spills off crankcase and frame.
NOTE:
Dispose of oil and oil filter in accordance with local regulations.
Oil Filter Wrenches
1. Oil filter mount
2. Oil filter
Oil Filter
Installing Oil Filter
NOTE:
Partially fill oil filter before installation to minimize the time required for buildup of oil pressure
when engine is first started.
1. Pour about 4 fl oz 120 mL of fresh, clean engine oil into new oil filter. Allow time for oil to
soak into filter element.
2. See Applying Thin Oil Film. Wipe filter gasket contact surface of oil filter mount with a
clean cloth. Surface should be smooth and free of any debris or old gasket material.
3. Apply a thin film of oil to gasket contact surface on crankcase (3) and gasket surface of new
oil filter.
NOTE:
Do not use oil filter wrench to install new oil filter.
4. Install new oil filter. Screw filter clockwise onto adapter until gasket contacts the filter mount
surface. Then hand tighten an additional 1/23/4turn to secure the oil filter.
1. Thin film of oil ONLY
2. Oil filter
3. Mounting plate
Applying Thin Oil Film
Refilling Oil Tank
NOTE:
Do not overfill the oil tank. The oil tank has a builtin pressure relief valve. If the oil tank is
overfilled, excessive pressure is created in the oil tank.The pressure relief valve will open to
relieve the pressure and prevent damage to the oil tank. Excessive oil due to overfilling will also
be forced out the pressure relief valve when it opens.
1. Refer to Recommended Engine Oils. Always use the proper grade of oil for the lowest
expected air temperature before the next regularly scheduled oil change. Pour 2.0 qt 1.9 L
of oil into engine oil tank.
2. Install filler cap/dipstick in oil tank. Verify cap is fully seated.
3. See Oil Pressure Indicator Lamp. Start engine. Verify that oil pressure signal lamp turns
off when engine speed is 1000 rpm or above. Turn engine off.
4. Check for oil leaks at oil filter and oil tank drain hose. Perform oil level hot check.
Oil Pressure Indicator Lamp
Winter Lubrication
Change engine oil often in colder climates. If motorcycle is frequently used for trips less than 15
mi 24 km , in ambient temperatures below 60 °F 16 °C , reduce oil change intervals to 1500 mi
2400 km .
NOTE:
The further below freezing the temperature drops, the shorter the oil change interval should be.
Water vapor is a normal byproduct of combustion in any engine. During cold weather operation,
some water vapor condenses to liquid form on the cool metal surfaces inside the engine. In
freezing weather this water will become slush or ice. Over time, accumulated slush or ice may
block the oil lines and cause engine damage.
If the engine is run frequently and allowed to thoroughly warm up, most of this water will become
vapor again and will be blown out through the crankcase breather.
If the engine is not run frequently and allowed to thoroughly warm up, this water will accumulate,
mix with the engine oil and form a sludge that is harmful to the engine.
Transmission Lubrication
Refer to Regular Service Intervals: 2012 Sportster Models. The transmission should be
drained and refilled with fresh lubricant at proper intervals. For best results, drain lubricant while
hot.
NOTE:
When checking the transmission lubricant level, motorcycle should be standing STRAIGHT UP,
not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize
lubricant level in the transmission compartments.
When draining or adding lubricant, do not allow dirt, debris
When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)
Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)
Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement,
incomplete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)
Check Lubricant Level
1. Ride motorcycle until engine is warmed up to normal operating temperature.
2. Position motorcycle straight up.
To prevent accidental vehicle startup, which could cause
death or serious injury, remove main fuse before
proceeding. (00251b)
3. Remove main fuse. See Fuses and Relays.
4. XL Models with MidMount Foot Controls: See MidMount Rider Footrest Assembly:
XL Models. Remove screws and detach the rider footrest support bracket from the left side
of the vehicle.
5. XR 1200X: See Rider Footrest Assembly (Left Side): XR 1200X. Remove screws and
detach the rider footrest support bracket from the left side of the vehicle. With the shift
linkage still attached, lower the footrest assembly to access the clutch inspection cover
screws.
6. See Primary Cover: XL Model. Remove screws with washers from clutch inspection
cover. Remove clutch inspection cover from primary cover.
NOTE:
The filler access is the clutch inspection cover.
7. See Chaincase Lubricant Level. Verify that lubricant level is even with bottom of clutch
diaphragm spring.
NOTE:
Add only enough of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE
LUBRICANT through clutch inspection cover opening until the lubricant reaches the bottom
of clutch diaphragm spring.
8. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install
clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to
90120 inlbs (10.213.6 Nm).
9. If the left footrest assembly was removed, install support bracket with two screws. Tighten
screws to 4550 ftlbs (61.067.8 Nm).
10. Install main fuse.
11. Start engine. Check for any lubricant leaks.
12. Turn engine off.
1. Clutch inspection cover
2. Drain plug
3. Primary chain inspection cover
Primary Cover: XL Model
1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Quadring
4. Primary cover
5. Chaincase lubricant level
Chaincase Lubricant Level
Changing Lubricant
1. Ride motorcycle until engine is warmed up to normal operating temperature.
2. When the engine reaches normal operating temperature, turn the engine off and position
motorcycle on jiffy stand. This will allow the chaincase lubricant to drain out of transmission.
4. See Primary Cover: XL Model. Position a suitable container under transmission drain
plug (2).
5. The drain plug is located under the clutch, on the underside of the primary cover. Remove
drain plug and drain lubricant.
6. Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be
drained from clutch compartment.
NOTE:
Dispose of lubricant in accordance with local regulations.
Do not overtighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)
7. Remove foreign material from magnetic drain plug. Replace the Oring if it is damaged.
8. Apply LOCTITE 565 PIPE SEALANT WITH TEFLON and install drain plug. Tighten to 1430
ftlbs (19.040.7 Nm).
9. See MidMount Rider Footrest Assembly: XL Models. For XL models equipped with
midmount foot controls, remove screws and detach the rider footrest support bracket from
the left side of the vehicle.
10. See Rider Footrest Assembly (Left Side): XR 1200X. For the XR 1200X, remove
screws and detach the rider footrest support bracket from the left side of the vehicle. With
the shift linkage still attached, lower the footrest assembly to access the clutch inspection
cover screws.
11. See Primary Cover: XL Model. Remove screws with washers from clutch inspection
cover. Remove clutch inspection cover from primary cover.
NOTE:
The filler access is the clutch inspection cover.
12. See Chaincase Lubricant Level. Add 1.00 U.S. qt 0.95 L of FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No. 9885105 qt) through clutch inspection
cover opening until the lubricant reaches the bottom of clutch diaphragm spring.
13. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install
clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to
90120 inlbs (10.213.6 Nm).
14. If the left footrest assembly was removed, install support bracket with two screws. Tighten
screws to 4550 ftlbs (61.067.8 Nm).
16. Start engine. Check for any lubricant leaks.
17. Turn engine off.
1. Support bracket
2. Screws (2)
MidMount Rider Footrest Assembly: XL
Models
1. Rider footrest support bracket
2. Screws (2)
3. Shift linkage
Rider Footrest Assembly (Left Side): XR
1200X
Primary Chain Adjustment
General
Refer to Regular Service Intervals: 2012 Sportster Models. Primary chain adjustment
should be checked at proper intervals and serviced as necessary. If the chain is allowed to run
loose, it will cause the motorcycle to jerk when running at low speed, and chain and sprockets will
wear excessively. If this happens, see a HarleyDavidson dealer or service manual for adjustment
procedure.
Primary Chain Freeplay Specifications
ENGINE in mm
Cold 3/81/2 9.512.7
Hot 1/43/8 6.39.5
1. Measurement point between sprockets
2. Free play measurement
Primary Chain Vertical Free Play: Sportster Models
Primary Chain Inspection
The primary chain can be inspected and if required, adjusted without removing the primary cover.
2. See Primary Cover: XL Model. Remove the two hex socket screws which secure primary
chain inspection cover (3).
3. See Primary Chain Vertical Free Play: Sportster Models. Check primary chain tension
by measuring vertical free play.
a. Measure vertical free play through chain inspection cover opening.
b. Rotate engine to move primary chain to a different position on sprockets.
c. Measure vertical free play several times, each time with primary chain moved so that
the measurement is taken with sprockets rotated to the tightest chain position.
4. The tightest measurement in previous step must be within the specifications listed in
Primary Chain Freeplay Specifications. If necessary, see PRIMARY CHAIN
ADJUSTMENT to adjust chain tension.
Primary Chain Adjustment
Do not adjust the primary chain tighter than specified.
Running chain too tight will result in excessive wear.
(00202a)
1. See Primary Chain Adjuster: Sportster Models. Loosen locknut (1).
2. Turn chain adjuster screw (2) clockwise (inward) to reduce free play or counterclockwise
(outward) to increase free play. Vertical free play must fall within the limits specified. Refer
to Primary Chain Freeplay Specifications.
NOTE:
If vertical free play cannot be set within the limits specified, then primary chain and/or chain
adjuster are worn beyond adjustment limits. Replace parts as necessary.
3. When tension is set correctly, hold chain adjusting screw and tighten locknut to 2025 ftlbs
(2734 Nm).
4. Install primary chain inspection cover and new gasket. Tighten hex socket screws to 90120
inlbs (10.213.6 Nm).
1. Locknut
2. Chain adjuster screw
3. Transmission chaincase drain plug
Primary Chain Adjuster: Sportster Models
Checking Drive Belt Deflection
General
Belt teeth are coated with polyethylene lubricant. Coating will wear off over time. This is not an
indicator of belt wear.
Gauging Deflection
Check belt deflection at the loosest spot in the belt with the transmission in neutral and the
motorcycle at ambient temperature.
1. With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE
HD35381A on the belt.
a. XL Models: See Gauging Belt Deflection: XL Models. Position the gauge halfway
between the transmission and rear wheel sprockets.
b. XR 1200X: See Gauging Belt Deflection: XR 1200X. Fit the tension gauge half
way between the idler wheel and rear sprocket.
2. With the BELT TENSION GAUGE set to 0 lb 0 kg , note the current belt position.
a. XL Models: See Belt Deflection Window: XL Models. View position through
window on drive belt guard.
b. XR 1200X: See Belt Deflection: XR 1200X. Check markings on front of debris
deflector.
3. Using the BELT TENSION GAUGE, apply 10 lb 4.5 kg of force to the bottom belt. Count the
number of graduations between the original belt position and after applying the force.
Multiply this number by 1/8 in 3.2 mm to determine the deflection.
4. Compare the deflection to specifications. Refer to Belt Deflection.
5. If belt tension adjustment is necessary, see a HarleyDavidson dealer or follow the belt
deflection adjustment procedure in the service manual.
Be sure wheel and brake caliper are aligned. Riding with a
misaligned wheel or brake caliper can cause the brake disc
to bind and lead to loss of control, which could result in
NOTE:
When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run
true within brake caliper.
Belt Deflection
MODELS in mm
XL 883R 9/165/8 14.315.9
Other XL models 1/45/16 6.47.9
XR 1200X 1/43/8 6.49.5
1. Transmission sprocket
2. Rear wheel sprocket
3. Force of 10 lb (4.5 kg)
4. Deflection (refer to table)
Gauging Belt Deflection: XL Models
1. Transmission sprocket
2. Rear wheel sprocket
3. Force of 10 lb (4.5 kg)
4. Deflection (refer to table)
5. Idler wheel
Gauging Belt Deflection: XR 1200X
1. Drive belt
2. Deflection graduations 1/8 in (3.2 mm) apart
Belt Deflection Window: XL Models
1. Drive belt
2. Deflection graduations 1/8 in (3.2 mm) apart
Belt Deflection: XR 1200X
Chassis Lubrication
Refer to Regular Service Intervals: 2012 Sportster Models for all maintenance schedules.
NOTE:
Use recommended SPECIAL PURPOSE GREASE for steering head bearings. Use a
multipurpose chassis grease for other applications.
1. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite.
2. Lubricate throttle control cables and clutch control cable with HARLEY LUBE.
3. Lubricate front brake hand lever and clutch control hand lever only if necessary.
4. Inspect rear fork pivot shaft bearings.
5. Pack the steering head bearings with SPECIAL PURPOSE GREASE at recommended
service intervals.
6. Lubricate the jiffy stand mechanism with SILVER GRADE ANTISEIZE.
NOTE:
For model specific information regarding the chassis lubrication, refer to the appropriate Service
Manual or see a HarleyDavidson dealer.
Oil Applications
Refer to Regular Service Intervals: 2012 Sportster Models for all control connections and
parts. Vehicle should be lubricated at regular intervals, particularly after washing motorcycle or
driving in wet weather.
Front Fork Oil
Refer to Regular Service Intervals: 2012 Sportster Models. Have a HarleyDavidson dealer
drain the front fork oil and refill at proper intervals. If fork does not appear to be working properly
or an appreciable amount of oil leakage should develop, see a HarleyDavidson dealer. If there is
insufficient oil in either side of fork, the rebound action will be incorrect.
Clutch
The clutch control cable must be oiled and adjusted
periodically to compensate for lining wear. See
MAINTENANCE SCHEDULING in this manual. Failure to oil
and adjust the clutch control cable can result in equipment
damage. (00203b)
The need for attention to clutch and controls will be indicated by the clutch slipping under load or
dragging when released. In this situation, check the control cable adjustment first. See a Harley
Davidson dealer for proper service.
Hydraulic Lifters
The hydraulic lifters are selfadjusting. They automatically adjust length to compensate for engine
expansion and valve mechanism wear. This keeps the valve mechanism free of lash when the
engine is running.
When starting an engine which has been turned off even for a few minutes, the valve mechanism
may be slightly noisy until the hydraulic units completely refill with oil. If at any time the valve
mechanism becomes abnormally noisy, other than for a short period immediately after engine is
started, it is an indication that one or more of the hydraulic units may not be functioning properly.
Always check the engine oil level first since normal circulation of oil through the engine is
necessary for proper operation of the hydraulic lifters.
If engine oil is at the proper level, the lifters may not be functioning properly because of dirt in the
oil supply passages leading to the lifter units. See a HarleyDavidson dealer for service.
Steering Head Bearings
Adjustments to steering head bearings should be
performed by a HarleyDavidson dealer. Improperly
adjusted bearings can adversely affect handling and
stability, which could result in death or serious injury.
(00051b)
Check for proper steering head bearing adjustment and lubricate bearings using SPECIAL
PURPOSE GREASE at proper intervals. Refer to Regular Service Intervals: 2012 Sportster
Models Service Intervals.
With motorcycle front end raised off the floor, be sure front fork turns freely without any binding or
interference and that there is no appreciable front to rear fork movement indicating excessive
bearing looseness. Steering head bearings should be adjusted according to service manual
procedure, if necessary.
Brakes
Brake Fluid
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is
performed. Failure to comply can result in cosmetic
damage. (00239b)
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can
cause digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause
improper operation and equipment damage. (00205c)
Clean filler cap before removing. Use only D.O.T. 4 brake
fluid from a sealed container. Contaminated fluid can
adversely affect braking, which could result in death or
1. Stand the motorcycle upright (not leaning on the jiffy stand) on a level surface, and turn
handlebar so the top of the brake master cylinder is level.
2. See Front Brake Fluid Sight Gauge and Rear Reservoir Level Guage. Look through
the sight glass on the front brake fluid reservoir and at the marks on the side of the rear
brake fluid reservoir to check the brake fluid level. If necessary, shine a flashlight on the rear
brake fluid reservoir to view the level.
The level in the sight glass or reservoir is the brake fluid level.
If the fluid level is below the minimum mark or not present, see a HarleyDavidson dealer.
NOTES:
If the brake system is not leaking, there should never be a need to add fluid. If the fluid level
is low, the pads are probably worn and need to be replaced. By replacing the pads, the fluid
level will rise.
Use only DOT 4 BRAKE FLUID and replace the brake fluid every two years. See a Harley
Davidson dealer.
3. Verify that the front brake lever and the rear brake pedal have a firm feel when applied. If
brakes are not firm, the brake system must be bled. See a HarleyDavidson dealer.
1. Front reservoir fluid level
2. Rear reservoir fluid level
Front Brake Fluid Sight Gauge and Rear
Reservoir Level Guage
Brake Pads
Inspect brake pads for wear at service maintenance
intervals. If you ride under adverse conditions (steep hills,
heavy traffic, etc.), inspect more frequently. Excessively
worn brake pads can lead to brake failure, which could
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
Brakes are a critical safety component. Contact a Harley
Davidson dealer for brake repair or replacement.
Improperly serviced brakes can adversely affect brake
(00054a)
Perform routine scheduled brake maintenance. Lack of
maintenance at recommended intervals can adversely
affect brake performance, which could result in death or
HarleyDavidson has equipped your new motorcycle with the optimum brake pad friction material
available. It is selected to give the best performance possible under dry or wet conditions and at
high operating temperatures. It exceeds all regulatory requirements currently in effect. However,
during some braking conditions you may experience noise. This is normal for this friction material.
Be sure wheel and brake caliper are aligned. Riding with a
misaligned wheel or brake caliper can cause the brake disc
to bind and lead to loss of control, which could result in
1. Check the rear brake disc as it spins. The disc should run true in the brake caliper.
2. See Brake Pad Friction Material (typical). Using a thin plastic ruler, measure the
thickness of the brake pad friction material. For rear brakes, place the ruler against the
brake disc through the space alongside the caliper.
1. Front brake, below
2. Rear brake, above
3. Pad thickness
Brake Pad Friction Material (typical)
3. If the brake pad friction material is at the minimum thickness or less, replace the pads.
Always replace brake pads in pairs. See a HarleyDavidson dealer. Refer to Minimum
Brake Pad Friction Material Thickness.
Minimum Brake Pad Friction Material Thickness
in mm
0.040 1.02
Tires
Refer to Tires: 2012 Sportster Models for specified tires and pressures.
Be sure to keep tires properly inflated.
Follow tire data for correct cold tire inflation pressures.
Check before riding when tires are cold.
Do not overinflate tires.
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a HarleyDavidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., at least weekly if in
daily use. Check before each trip if used occasionally.
Same as original equipment tires should be used. Other tires may not fit correctly, could adversely
affect handling, and may be hazardous to use.
Tires are a critical safety component. Contact a Harley
Davidson dealer for tire repair or replacement. Improper
tire service can adversely affect stability and handling,
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a HarleyDavidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)
Striking an object, such as a curb or pothole can cause
internal tire damage. If an object is struck, have the tire
inspected immediately inside and out by a Harley
Davidson dealer. A damaged tire can fail while riding and
Tire Replacement
Tread Wear
Replace tire immediately with a HarleyDavidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)
HarleyDavidson tires are equipped with wear bars that run horizontally across the tread. When a
tire is worn to the point that the wear bars are visible, or 1/32 in. 0.8 mm tread depth remains, the
tire can:
Be more easily damaged leading to tire failure.
Provide reduced traction.
Adversely affect stability and handling.
Replace the tires with new tires before the tread wear bars appear:
See Tread Pattern: Michelin Tires or Tread Pattern: Dunlop Tires. Indicators (1) on
the tire sidewalls point to tread wear bars (2) in the tread.
Tread wear bars appear in the tread pattern when 1/32 in 0.8 mm or less of tread remains.
1. Indicator
2. Tread wear bar
Tread Pattern: Michelin Tires
1. Indicator
2. Tread wear bar
Tread Pattern: Dunlop Tires
Tire Damage
Replace tires with new tires when:
Tire cords or fabric are visible through cracked sidewalls, snags or deep cuts.
A bump, bulge or split is found anywhere on the tire.
A puncture, cut or other damage cannot be repaired.
Shock Absorbers
Inspect shock absorbers and rubber bushings for leaks and bushing deterioration at proper
intervals.
XR 1200X Model
XR 1200X shock absorbers contain pressurized gas. Visually inspect the shock absorbers while
observing the following precautions.
Shock absorber cannot be serviced. Attempting service
can cause an explosion, which could result in death or
serious injury. (00602d)
Do not refill, disassemble, puncture or expose shock to flames.
Replacement and disposal should only be done by an authorized HarleyDavidson dealer.
Spark Plugs
Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)
Do NOT pull on any electrical wires. Pulling on electrical
wires may damage the internal conductor causing high
resistance, which may result in minor or moderate injury.
(00168a)
Check the spark plugs at proper intervals. Refer to Regular Service Intervals: 2012
Sportster Models.
1. Disconnect spark plug cables from plugs by pulling up on the molded connector caps.
2. Check spark plug type. Only use those spark plugs specified for your model motorcycle.
3. Check spark plug gap against specifications table.
NOTE:
If a torque wrench is not available, tighten new spark plugs fingertight and then tighten an
additional onequarter turn with a spark plug wrench.
4. Always tighten to the proper torque. Spark plugs must be tightened to the torque specified
for proper heat transfer. Refer to Electrical: XL Models or Electrical: XR 1200X.
5. Connect each molded connector cap until the cap snaps firmly into place over the spark
plug.
Ignition
The engine in your motorcycle has been designed specifically to achieve optimum fuel economy
within exhaust emission controls. Factory programmed ignition characteristics provide maximum
engine performance and driveability.
Air Cleaner
XL Models: Removal
Install air filter before running engine. Failure to do so can
draw debris into the engine and could result in engine
damage. (00207a)
NOTES:
At regular intervals, inspect the air filter element. Under dusty conditions, inspect more
often. Refer to Regular Service Intervals: 2012 Sportster Models.
XL Models except XL 1200V: See Air Cleaner: XL Models except XL 1200V.
XL 1200V: See Air Cleaner: XL 1200V.
1. Remove the cover screw(s), trim (except XL 1200V) and the air cleaner cover.
2. Inspect the filter element.
3. Remove and clean the air filter element if necessary.
1. Cover screw (2)
2. Trim
3. Cover
4. Filter element
5. Oring (2)
6. Gasket
7. Element screw (3)
8. Seal
Air Cleaner: XL Models except XL 1200V
1. Cover screw
2. Cover
3. Filter element
4. Oring (2)
5. Gasket
6. Element screw (3)
7. Seal
Air Cleaner: XL 1200V
Cleaning Filter Element
Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)
NOTES:
Do not tap the filter on a hard surface to dislodge dirt.
Replace the filter element if damaged or if the element cannot be cleaned.
1. Wash the filter in warm soapy water.
NOTE:
The filter is clean if light is visible through it.
2. Hold the filter up to a light.
NOTE:
Do NOT use air cleaner filter oil on the paper/wire mesh element.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
3. Air dry or blow dry the filter from the inside with low pressure air.
XL Models: Installation
Air Cleaner Fastener Torque: All XL Models
FASTENER TORQUE
Air filter element screws 4060 inlbs (4.56.8 Nm)
Air filter cover screw 3660 inlbs (4.16.8 Nm)
NOTE:
Check that the Orings on the breather tubes are in place.
1. If removed, install the baseplate gasket and the air filter element with the screws. Tighten to
specification. Refer to Air Cleaner Fastener Torque: All XL Models.
2. Install the air cleaner cover with the air cleaner seal.
3. Apply a drop of LOCTITE THREADLOCKER 243 (blue) to the threads of the cover screw(s).
4. Install the trim (except XL 1200V) and the screw(s). Tighten to specification. Refer to Air
Cleaner Fastener Torque: All XL Models.
XR 1200X
Remove all debris from the air cleaner cover inlet. See a HarleyDavidson dealer or service
manual at specified intervals for filter element inspection or replacement. Under dusty conditions,
inspect more often. Refer to Regular Service Intervals: 2012 Sportster Models.
Headlamp Bulb
Removal
When replacement is required, use only the specified
sealed beam unit or bulb, available from a HarleyDavidson
dealer. An improper wattage sealed beam or bulb, can
cause charging system problems. (00209a)
2. Remove the trim ring.
a. XL 883L/N/R, XL 1200N/X, XR 1200X: See Headlamp Assembly: XL 883L/N/R,
XL 1200N/X, XR 1200X. Remove screw (1), nut (2) and headlamp trim ring (3).
Refer to Legend Headlamp Assembly: XL 883L/N/R, XL 1200N, XR 1200X.
b. XL 1200C/CP/V: See Headlamp Assembly: XL 1200C/CP/V. Remove screw (1)
and headlamp trim ring (2). Refer to Legend Headlamp Assembly: XL
1200C/CP/V.
3. Hold headlamp reflector/lens and compress release tabs on sides of bulb connector (11) to
pull connector from the bulb (7) spade terminals.
4. Remove headlamp lens and metal adapter ring.
5. Pull rubber boot from back of the lens.
6. Press ends of retaining clip (8) to unhook from notched retaining tabs and pivot retaining clip
back.
7. Remove the bulb.
Installation
Handle bulb carefully and wear eye protection. Bulb
contains gas under pressure, which, if not handled
carefully, could cause serious eye injury. (00062b)
Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Handle the bulb with paper or
a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
1. Install the replacement bulb.
NOTE:
Fit the tab opposite the center spade connector of bulb to the top notch in the reflector.
2. Pivot the retaining clip over the bulb and press the ends into the retaining post.
3. Install rubber boot with word TOP over top notch.
4. Press center ring down flush with base of bulb. Press air out of boot to seal bore of boot to
bulb.
NOTE:
Air will enter the rubber boot and raise the center ring above bottom of bulb.
5. Connect the bulb connector to the bulb.
6. Install the lens.
a. XL 883L/N/R, XL 1200N/X, XR 1200X: Fit the adapter ring and the reflector/lens to the
headlamp shell.
b. XL 1200C/CP/V: With the finger gasket in place, fit the adapter ring and the
reflector/lens to the headlamp shell.
NOTES:
Fit the two notches on the circumference of the adapter ring to the two bulges on rim
of headlamp shell.
Fit the single tab on the circumference of the reflector to the notch on the inside of the
adapter ring.
7. Rotate the trim ring clockwise to lock down on the reflector/lens. Install the trim ring screw,
nut as necessary and tighten.
8. Install the main fuse.
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
9. Test operation of the headlamp.
10. Align the headlamp. See Headlamp Alignment.
Position Lamp: HDI
1. Replace the position lamp if necessary.
2. Pull the spade connectors from the bulb holder.
3. Pull the bulb holder from the reflector/lens.
4. Quarter turn the bulb to remove and replace.
5. Replace the bulb holder and mate connectors.
Headlamp Assembly: XL 883L/N/R, XL
1200N/X, XR 1200X
Legend Headlamp Assembly: XL 883L/N/R, XL 1200N, XR 1200X
LEGEND NO. COMPONENT
1 Screw
2 Nut
3 Trim ring
4 Lens
5 Bulb shield
6 Position lamp (HDI models)
7 Wire clip
8 Bulb
9 Rubber boot
10 Adapter ring
11 Connector [5]
12 Position lamp connectors
HDI models
Headlamp Assembly: XL 1200C/CP/V
Legend Headlamp Assembly: XL 1200C/CP/V
LEGEND NO. COMPONENT
1 Screw
2 Trim ring
3 Lens
4 Finger gasket
5 Bulb shield
6 Position lamp (HDI models)
7 Wire clip
8 Bulb
9 Rubber boot
10 Adapter ring
11 Connector [5]
12 Position lamp connectors
HDI models
Headlamp Alignment
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
NOTE:
Adjust the headlamps of motorcycles with multiple beam headlamps to converge into one pattern.
1. Check the tire pressure.
2. Adjust the rear shocks for the rider and intended load.
3. Fill fuel tank or add an equal amount of ballast.
NOTE:
Choose a wall in minimum light.
4. See Headlamp Alignment: Sportster Models. Park the motorcycle in a line (1)
perpendicular to the wall.
5. Position motorcycle so that front axle is 25 ft 7.6 m from wall.
6. Draw a vertical line (2) on the wall.
7. With the motorcycle loaded, point the front wheel straight forward at wall. Measure the
distance (4) from the floor to the center of the high beam bulb.
8. Draw a horizontal line (5) through the vertical line on the wall that is 2.1 in 53.3 mm lower
than the measured bulb centerline.
NOTE:
The headlamp is aligned when the light beam hot spot is centered over the intersection of
the lines.
9. Verify headlamp alignment.
10. Adjust headlamp if necessary.
1. Perpendicular line
2. Vertical line
3. 25 ft (7.6 m)
4. High beam bulb centerline
5. Horizontal line 2.1 in (53.3 mm) lower than bulb centerline
Headlamp Alignment: Sportster Models
Headlamp: Adjustment
Adjustment: XL 1200X/C/CP/V
1. Set horizontal adjustment:
a. See Headlamp Adjustment: XL 1200X/C/CP/V. Loosen the horizontal adjustment
screw (3).
b. Turn the headlamp right or left as necessary to direct the light beam straight ahead.
c. Tighten the horizontal adjustment screw to 3035 ftlbs (40.747.5 Nm).
2. Set vertical adjustment:
a. Loosen the locknut (1) for the vertical adjustment bolt.
b. Tilt headlamp up or down to properly aim it at the horizontal line on the wall.
c. Tighten headlamp locknut to 3035 ftlbs (40.747.5 Nm).
1. Locknut
2. Vertical adjustment bolt
3. Horizontal adjustment screw
Headlamp Adjustment: XL 1200X/C/CP/V
Adjustment: XL 883R/L/N, XL 1200N, XR 1200X
1. See Headlamp Adjustment: XL 883R/L/N, XL 1200N/X, XR 1200X (XR 1200X
shown). Remove snap plug (1) on top of headlamp bracket (2).
2. Loosen headlamp clamp nut (3).
3. Tilt headlamp up or down to properly aim it in relation to the horizontal line and, at the same
time, turn it right or left to direct light beam straight ahead.
4. Tighten headlamp clamp nut to 120240 inlbs (1427 Nm) after lamp is properly positioned.
5. Install snap plug in headlamp bracket.
1. Snap plug
2. Headlamp bracket
3. Clamp nut
Headlamp Adjustment: XL 883R/L/N, XL
1200N/X, XR 1200X (XR 1200X shown)
Turn Signal Bulb Replacement: Bullet Style
1. See Lens Cap Notch. Insert a coin or the blade of a small screwdriver into the notch at the
bottom of the lens cap. Carefully twist until the lens cap pops out of the lamp housing.
2. Push bulb in and rotate counterclockwise. Pull bulb from socket.
3. Inspect condition of electrical contacts in socket. If necessary, clean with a small wire brush
and electrical contact cleaner.
4. Coat base of new bulb with ELECTRICAL CONTACT LUBRICANT.
5. Align pins on bulb with pin guides in bulb socket. Push new bulb in and turn clockwise to
lock in place.
6. Snap lens cap back into the lamp holder. Rotate lens to position notch at bottom of lamp.
7. Turn ignition on and test for proper operation.
Lens Cap Notch
Tail Lamp Bulb Replacement
XL 883R/L, XR 1200X and Models with Standard Style Tail Lamp
1. Turn ignition switch OFF.
2. See Tail Lamp Assembly. Remove two screws and lens from base.
NOTE:
For ease of bulb removal, the 4Pin multilock connector can be removed from circuit board.
3. Pull bulb assembly from lens. Remove bulb from socket.
4. Coat base of new bulb with ELECTRICAL CONTACT GREASE. Install new bulb in socket.
5. Install (push) bulb assembly to lens.
6. If removed, connect [93] connector to circuit board.
7. Install lens to base with two screws. Tighten to 2024 inlbs (2.32.7 Nm).
8. Turn ignition on and test for proper tail lamp operation.
1. Lens
2. Base
3. 4pin multilock connector
4. Bulb socket
Tail Lamp Assembly
XL 1200C/CP
Though similar in appearance to the standard style tail lamp, the tail lamp on XL 1200C/CP
models is an LED assembly. See a dealer or service manual for replacement.
XL 883N and XL 1200N/X/V
The tail and stop lamps are dual filament turn bulbs in the rear turn signal bullet housings with red
lenses. To replace a tail or stop lamp, replace the turn signal bulbs. See Turn Signal Bulb
Replacement: Bullet Style.
XL 883N and XL 1200N/X/V Models with LED Turn Signal Tail and
Stop Lamps
On International and Japanese XL 883N and XL 1200N/X/V models, the rear turn signal/tail lamps
are LED assemblies. There are not replacement bulbs for this style lamp. The caps on the rear
turn signals are not removeable. See a dealer or service manual for assembly replacement.
Due to local regulations, this feature may not be found in all destinations.
Alternator/Voltage Regulator
Charging Rate
The alternator output is controlled and changed to direct current by the voltage regulator.
The voltage regulator increases charging rate when battery is low or lamps are lit.
The voltage regulator decreases charging rate when battery charge is up.
It is possible to overload your vehicle's charging system
by adding too many electrical accessories. If the combined
electrical accessories operating at any one time consume
more electrical current than the vehicle's charging system
can produce, the electrical consumption can discharge the
battery and cause damage to the vehicle's electrical
system. See an authorized HarleyDavidson dealer for
advice about the amount of current consumed by
additional electrical accessories or for necessary wiring
changes. (00211c)
NOTES:
This unit requires no interval attention. If any electrical system trouble is experienced that
might be traceable to the alternator or voltage regulator, the motorcycle should be taken to a
HarleyDavidson dealer who has the necessary electrical testing equipment to give the
required attention.
For model specific information regarding the voltage regulator, refer to the appropriate
Service Manual or see a HarleyDavidson dealer.
Left Side Cover
The left side cover provides access to the main fuse holder, battery and fuse/relay block. No tools
are required to remove or install the side cover.
Opening
NOTES:
The left side cover does not need to be completely removed from the vehicle to access the
battery or fuses.
Place a shop cloth or other clean, dry cloth over rear brake master cylinder reservoir and left
passenger foot peg (if applicable). This will protect cover from damage.
1. See Left Side Cover (XL model shown). Grasp left side cover at upper corners and
gently pull away from frame. On XL models, disengage the rear clip first for easier opening.
2. While rotating top of cover out away from motorcycle, slide cover down slightly so mounting
slot slides down from mounting tab on battery tray.
Closing
1. Raise the left side cover.
2. On XL models, align the barrel clips on the cover with the socket clips on the frame. Press
the cover to secure.
3. On the XR 1200X, align the locating pins with the grommets on the frame. Press the cover
to secure.
1. Barrel clips on cover
2. Socket clips on frame
Left Side Cover (XL model shown)
Battery
Type
Your motorcycle uses an Absorbed Glass Mat (AGM) battery that is permanently sealed, valve
regulated, maintenancefree, lead/calcium and sulfuric acid battery. All batteries are shipped
precharged and ready to be put into service. Do not attempt to open the battery for any reason.
Antidotes for Battery Acid
CONTACT TREATMENT
External Flush with water.
Internal Drink large quantities of milk or water,
followed by milk of magnesia, vegetable oil
or beaten eggs. Get immediate medical
attention.
Eyes Flush with water. Get immediate medical
attention.
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
wellventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
defects or other reproductive harm. Wash hands after
handling. (00019e)
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)
1. Contents are corrosive
2. Wear safety glasses
3. Contents are explosive
4. Keep flames away
5. Read instructions
6. Keep away from children
Battery Warning Label
Battery Warning Label
Voltmeter Test
The voltmeter test provides a general indicator of battery condition. Check the voltage of the
battery to verify that it is in a 100 percent fullycharged condition. If the open circuit (disconnected)
voltage reading is below 12.7 V, charge the battery and then recheck the voltage after the battery
has set for one to two hours. Refer to Voltmeter Test.
Voltmeter Test
READING IN VOLTS PERCENT OF CHARGE
12.7 100
12.6 75
12.3 50
12.0 25
11.8 0
Cleaning and Inspection
Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to
selfdischarge.
1. Clean battery top.
2. Clean cable connectors and battery terminals using a wire brush or fine grit sandpaper to
remove any oxidation.
3. Inspect and clean the battery screws, clamps and cables. Check for breakage, loose
connections and corrosion.
4. Check the battery posts for melting or damage caused by overtightening.
5. Inspect the battery for discoloration, a raised top or a warped or distorted case. This might
indicate that the battery has been frozen, overheated or overcharged.
6. Inspect the battery case for cracks or leaks.
Charging
An automatic, constant monitoring battery charger/tender with a charging rate of 5 amps or less at
less than 14.6 volts is recommended. The use of constant current chargers (including trickle
chargers) to charge sealed AGM batteries is not recommended. Any overcharge will cause dry
out and premature battery failure. Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's instructions, follow these general
safety precautions.
Charge the battery if any of the following conditions exist:
Vehicle lamps appear dim.
Electric starter sounds weak.
Battery has not been used for an extended period of time.
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
1. Perform a voltmeter test to determine the state of charge. If battery needs to be charged,
proceed to the next step.
2. Place the battery on a level surface.
Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative () cable connected,
the resulting sparks can cause a battery explosion, which
Disconnect negative () battery cable first. If positive (+)
cable should contact ground with negative () cable
connected, the resulting sparks can cause a battery
explosion, which could result in death or serious injury.
(00049a)
Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)
NOTES:
Do not use chargers with excessively high voltage designed for flooded batteries or
excessively high current designed for much larger batteries. Charging should be
limited to no more than 5 amps at no more than 14.6 volts.
Most automatic, constant monitoring battery chargers are completely automatic and
can be left connected to both AC power and to the battery that is being charged. When
leaving this type of charger connected for extended periods of time, periodically check
the battery to see if it is unusually warm. This is an indication that the battery may
have a weak cell or internal short. Read the manufacturers instructions for the charger
being used.
3. Connect the red battery charger lead to positive (+) terminal of the battery.
4. Connect the black battery charger lead to negative () terminal of the battery.
NOTE:
If the battery is still in the vehicle, connect the negative lead to the chassis ground. Make
sure that the ignition and all electrical accessories are turned off.
5. Step away from the battery and turn on the charger.
Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion,
6. After the battery is fully charged, turn OFF the charger and disconnect the black battery
charger lead to the negative () terminal of the battery.
7. Disconnect the red battery charger lead to the positive (+) terminal of the battery.
8. Mark the charging date on the battery.
Storage
If the motorcycle will not be operated for several weeks, such as during the winter season,
remove the battery from the motorcycle and fully charge.
If the motorcycle is to be stored with the battery installed, it will be necessary to connect a
automatic, constant monitoring charger/tender to maintain charge. See an authorized dealer for
more information.
A battery that is removed from the vehicle is affected by selfdischarge. A battery that is stored in
the vehicle is affected by both selfdischarge and, more significantly, parasitic loads. Parasitic
loads occur from things like diode leakage and maintaining computer memory with the vehicle off.
Batteries selfdischarge at a faster rate at higher ambient temperatures.
To reduce the selfdischarge rate, store battery in a cool, dry place.
Charge the battery every two weeks if stored in the vehicle.
Charge the battery once per month if stored out of the vehicle.
1. Capacity
2. Months of nonuse
3. Measured at 105 °F (40 °C)
4. Measured at 77 °F (25 °C)
Effective Rate of Temperature on Battery
Selfdischarging Rate
Battery Disconnection and Removal
Disconnect negative () battery cable first. If positive (+)
cable should contact ground with negative () cable
connected, the resulting sparks can cause a battery
explosion, which could result in death or serious injury.
(00049a)
1. Open left side cover.
NOTE:
Models with Sirens: Verify that fob is present and turn ignition key to IGNITION before
removing main fuse or disconnecting battery.
2. See Negative () Battery Connection. Using a swivel socket (2), remove nut that
secures the negative () battery cable (1) connector to ground stud (4) on crankcase boss
behind starter motor assembly (3). Remove cable connector from stud.
3. See Negative () Battery Cable Holder. Pull end of negative () cable (2) forward gently
to free it from cable holder (1).
4. See Main Fuse and Battery Location: All Models. Press main fuse holder (1) toward
the rear of the motorcycle until it pops off its mounting pin on battery strap (4). Remove main
fuse holder from battery strap.
5. Press data link connector (6) toward the rear of the motorcycle until it pops off its mounting
pin on battery strap. Remove the connector from battery strap.
6. Remove battery strap screw (5). Unhook battery strap from battery tray mount on top of
battery and remove strap.
7. Lift up protective rubber boot covering battery positive (+) terminal (3). Remove screw from
battery positive (+) terminal and remove positive (+) battery cable.
8. Disconnect positive (+) battery cable from cable holder (2).
9. Slide the battery (with attached negative cable) out from the left side of the vehicle until the
negative battery cable is accessible.
10. Disconnect the negative battery cable at the battery () terminal. Leave the cable on the
vehicle.
11. Remove battery from battery tray. Note routing of negative () battery cable around frame
downtube.
12. If battery is to be left out of vehicle (i.e. winter storage), close left side cover.
1. Negative () battery cable
2. Swivel socket
3. Starter motor assembly
4. Ground stud
Negative () Battery Connection
1. Cable holder
2. Negative battery cable
Negative () Battery Cable Holder
1. Main fuse and holder
2. Positive (+) battery cable holder
3. Positive (+) battery terminal (under protective rubber boot)
4. Battery strap
5. Screw
6. Data link connector
Main Fuse and Battery Location: All Models
Battery Installation and Connection
Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle
electrical system. (00215a)
1. Open left side cover.
2. Apply a light coat of petroleum jelly or corrosion retardant material to the negative () battery
terminal.
3. Slide fully charged battery into battery tray.
4. Insert screw through negative battery cable and into negative battery terminal. Thread screw
into terminal. Tighten screw to 6070 inlbs (6.87.9 Nm).
5. Verify that the negative () battery cable is disconnected from the ground stud on crankcase,
6. Hook top of battery strap (4) to battery tray mount on top of battery. Install strap screw (5).
Tighten to 3660 inlbs (4.16.8 Nm).
7. Route main positive battery cable through holders on electrical bracket.
8. Hook main fuse holder (1) to top pin on battery strap and slide forward until it snaps into
place.
9. Hook data link connector (6) to bottom pin on battery strap and slide forward until it snaps
into place.
10. See Negative () Battery Cable Holder. Press negative () battery cable (2) into cable
holder (1).
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative () cable connected,
the resulting sparks can cause a battery explosion, which
11. See Main Fuse and Battery Location: All Models. With negative battery cable
disconnected, insert positive terminal screw through main fuse cable then main positive
battery cable. Install screw into positive battery terminal (3). Tighten to 6070 inlbs (6.87.9
Nm).
12. Apply a light coat of petroleum jelly or corrosion retardant material to the positive (+) battery
terminal. Place protective rubber boot over terminal.
13. See Negative () Battery Connection. Place negative () battery cable connector onto
ground stud (4) on crankcase boss behind starter motor assembly (3). Thread nut onto stud.
14. See Attaching Negative () Battery Cable to Ground Stud Crankcase: XL Models
or Attaching Negative () Battery Cable to Ground Stud Crankcase: XR 1200X.
Press negative () battery cable connector (1) against cable stop (2) on crankcase and
tighten nut (3) to 5575 inlbs (6.28.5 Nm).
15. Close left side cover.
1. Negative battery cable connector
2. Cable stop
3. Nut
Attaching Negative () Battery Cable to Ground
Stud Crankcase: XL Models
1. Negative battery cable connector
2. Cable stop
3. Nut
Attaching Negative () Battery Cable to Ground
Stud Crankcase: XR 1200X
Jump Starting
Jump starting a motorcycle is typically not recommended. However, there may be circumstances
when it is necessary to do so. If a jumpstart is necessary, use the following procedure.
Be sure jumper cables touch only appropriate battery
terminals or ground. Allowing jumper cables to touch each
other can result in sparks and a battery explosion, which
Be sure both vehicles have the same battery voltage when
jump starting. Connecting vehicles with different system
voltages can result in vehicle damage. (00220c)
NOTES:
This procedure presumes the BOOSTER battery is in another vehicle. DO NOT jump start
from a running booster vehicle. The high output charging systems on some vehicles can
damage the electrical components on the motorcycle.
Make sure the motorcycle and the BOOSTER vehicle are not touching one another.
1. Turn off all unnecessary lamps and accessories.
Positive Cable
2. See Jump Start Cable Connections. Connect one end of a jumper cable to the
DISCHARGED battery positive (+) terminal (1).
3. Connect the other end of the same cable to the BOOSTER battery positive (+) terminal (2).
Negative Cable
Do not connect negative () cable to or near the discharged
battery negative () terminal. Doing so could cause a spark
and explosion, which could result in death or serious
injury. (00073a)
4. Connect one end of a jumper cable to the BOOSTER battery negative () terminal (3).
Do not connect the negative () cable to painted or chrome
parts. Doing so could result in discoloration at the
attachment point. (00221a)
5. Connect other end of the same cable (4) to a safe ground, (away from the DISCHARGED
battery).
6. Start motorcycle.
7. Disconnect cables in reverse order of Steps 2, 3, 4, 5; that is: Steps 5, 4, 3, 2.
1. Discharged battery positive (+) terminal
2. Booster battery positive (+) terminal
3. Booster battery negative () terminal
4. Ground
Jump Start Cable Connections
Fuses and Relays
Fuse Replacement
Always use replacement fuses that are of the correct type
and amperage rating. Use of incorrect fuses can result in
damage to electrical systems. (00222a)
See Fuse Block. The fuse block is located behind the left side cover.
If replacing a fuse does not correct the problem, or if a fuse is repeatedly blown, see a Harley
Davidson dealer to diagnose any possible electrical problems.
1. Turn the ignition to the OFF position.
2. Open left side cover. See Left Side Cover.
3. See Fuse Block. Push tab to release the fuse block cover.
4. See Relay and Fuse Locations. Remove the suspect fuse and inspect the element.
5. If the element is burned or separated, replace the fuse with a properly rated automotive type
ATO fuse.
6. Align fuse block cover with retaining guide. Slide the fuse block cover until tab latches.
7. Close left side cover.
Main Fuse
See Removing/Installing Main Fuse. The 30 amp main fuse can be removed to disconnect
power from the motorcycle's entire electrical system (except starter motor/solenoid). The main
fuse is located behind the left side cover.
To prevent the security system siren from sounding (if equipped), turn the ignition switch ON with
the handsfree fob present to disarm the security system before removing the main fuse.
To remove, grasp the fuse holder in one hand and the plastic body of the main fuse in the other.
Pull the main fuse straight out of the fuse holder.
1. Fuse block cover
2. Tab
3. Retaining guide
4. Main fuse
Fuse Block
1. System relay
2. Starter relay
3. Ignition
4. Lights
5. Accessory
6. ECM
7. Battery
8. Spare
Relay and Fuse Locations
1. Main fuse
2. Fuse holder [5]
Removing/Installing Main Fuse
Seat: XL Models
Removal
1. Remove screw to detach seat from rear fender.
2. Slide seat forward.
3. See Seat Post: XL Models. Lift up slightly to detach keyhole bracket from seat post.
NOTES:
Solo Seat: See Seat: XL Solo.
TwoUp Seat: See Seat: XL TwoUp.
4. Slide seat rearward to detach seat tongue (1) from rear fuel tank bracket.
5. Verify that tongue and mounting bracket (3) are tightly secured to the seat bottom.
NOTE:
The passenger strap is not sold separately. Replace entire seat if the strap is damaged.
6. If twoup seat, inspect passenger strap (4) for damage or excessive wear.
Seat Post: XL Models
1. Tongue
2. Keyhole
3. Mounting bracket
Seat: XL Solo
1. Tongue
2. Keyhole
3. Mounting bracket
4. Passenger strap
Seat: XL TwoUp
Installation
1. Position seat on frame with mounting bracket at rear.
2. Slide seat forward until the tongue fits snugly under rear fuel tank bracket.
3. Push seat forward to engage keyhole onto seat post. Pull seat back slightly.
NOTE:
Mounting bracket of solo seat uses forward hole in rear fender. Dual seat bracket uses
rearward hole.
4. See Seat Assembly: Sportster XL Models. Install seat mounting screw with captive
washer (3) to fasten seat mounting bracket to top of rear fender.
5. Pull up on seat to verify that it is locked in place.
6. Tighten seat mounting screw to 2040 inlbs (2.34.5 Nm).
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
7. Pull up on seat again to verify that it is secured at all three points.
1. Seat mounting screw with captive washer
2. Seat assembly, twoup (typical)
3. Seat assembly, solo (typical)
4. Passenger strap (not sold separately)
Seat Assembly: Sportster XL Models
Seat: XR 1200X
Removal
1. See Front Seat Tabs (under tailsection): XR 1200X. Reach under front end of
tailsection. Press the two seat tabs inward.
2. Pull front of seat upward to disengage seat from the front end of the tailsection.
3. Pull seat forward over fuel tank.
NOTES:
When removing the seat, verify that the mounting bracket under the seat is tightly secured to
the seat bottom.
Check for loose or missing rivets.
Inspect passenger strap for damage or excessive wear. The passenger strap is not sold
separately. Replace entire seat if the strap is damaged.
Front Seat Tabs (under tailsection): XR
1200X
Installation
1. See Seat and Pillion: XR 1200X. Align the guides in the seat bracket with the seat posts.
Place rear of seat into tailsection.
2. Push down on front of seat until the two tabs engage the front end of tailsection.
1. Seat
2. Seat tabs
3. Seat posts
4. Passenger pillion
5. Pillion tabs
6. Pillion seat post
Seat and Pillion: XR 1200X
Passenger Pillion: XR 1200X
Removal
1. See Passenger Pillion: XR 1200X. Lift the rear of pillion to disengage grommet from the
seat post.
2. Pull pillion out from tailsection.
Installation
1. See Passenger Pillion: XR 1200X. Insert pillion into trunk, aligning tabs on pillion with the
slots in the trunk.
2. Push down firmly on rear of pillion until grommet fully engages the seat post.
1. Pillion
2. Tabs
3. Seat post
Passenger Pillion: XR 1200X
Motorcycle Storage
Placing Motorcycle in Storage
Proper storage is important for the troublefree operation
of your motorcycle. See your Owner's Manual for storage
recommendations or see a HarleyDavidson dealer.
Improper storage procedures can lead to equipment
damage. (00046a)
If the motorcycle will not be operated for several months, such as during the winter season, there
are several tasks which should be performed. These steps will protect parts against corrosion,
preserve the battery and prevent the buildup of gum and varnish in the fuel system.
Store the motorcycle in a dry area with a stable temperature (if possible), away from any harsh
chemicals or other substances such as fertilizers or salt.
NOTE:
Make a list of everything you do and fasten it to a handgrip. When you take the motorcycle out of
storage, this list will be your reference/checklist to get your motorcycle in operating condition.
1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline
stabilizers and follow the manufacturer's instructions.
2. Warm motorcycle to operating temperature. Change oil and turn engine over to circulate the
new oil.
3. Check and adjust belt if necessary.
4. Check tire pressure. Refer to Tires: 2012 Sportster Models for specified pressure.
5. To protect the vehicle's body panels, engine, chassis and wheels from corrosion, follow the
cosmetic care procedures described in the Care and Cleaning section of this owner's
manual prior to storage.
6. Prepare battery for winter storage. See Battery.
NOTE:
If the motorcycle will be stored with the security system armed, connect a 750Ma
SUPERSMART BATTERY TENDER 9465498B to maintain battery charge.
If the motorcycle will be stored with the security system disarmed, turn the motorcycle
on while the handsfree fob is present. This will prevent the optional siren from
sounding. Disconnect the negative battery cable and prepare battery for storage. See
Battery.
7. If motorcycle is to be covered, use a material such as light canvas that will breathe. Plastic
materials that do not breathe promote the formation of condensation. Do not bend or tuck
antennas under the cover. Either remove the antennas (if equipped) or allow them to
protrude through the cover.
Removing Motorcycle From Storage
The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place
transmission in gear and push vehicle back and forth
several times to assure proper clutch disengagement.
(00075a)
NOTE:
When lubricants have been contaminated by water, they often take on a milky white appearance.
Always drain contaminated lubricants and refill with the appropriate HarleyDavidson lubricant
prior to motorcycle operation.
1. See Battery for proper battery care. Charge and install the battery.
2. Start the engine and run until it reaches normal operating temperature. Turn off engine.
3. Check amount of oil in the oil tank.
4. Check the transmission lubricant level.
5. Check controls to be sure they are operating properly. Operate the front and rear brakes,
throttle, clutch and shifter.
6. Check steering for smoothness by turning the handlebars through the full operating range.
7. Check tire pressure. Refer to Tires: 2012 Sportster Models for specified pressure.
8. Check overall tire condition. See Tire Replacement.
9. Check all electrical equipment and switches including the stop lamp, turn signals and horn
for proper operation.
10. Check for any fuel, oil or brake fluid leaks.
Turn engine over a few times to be sure there is no oil in
the crankcase and that all oil has been pumped back into
the oil tank. Stop engine and recheck oil level. Failure to
do so can result in engine damage. (00071a)
Care and Cleaning
Cleaning and General Care
Clean and protect the cosmetic surfaces on your motorcycle as often as possible to inhibit rust
and corrosion. After the motorcycle is cleaned, polish and seal the motorcycle to create a
sacrificial barrier of protection against the weather and harsh substances.
Refer to Recommended Cleaning and Care Products and Recommended Surface Care
Products. HarleyDavidson cleaning products are tested extensively for use on vehicle surfaces
and are formulated to be compatible with one another. See a HarleyDavidson dealer to purchase
recommended cleaning products.
NOTES:
Use recommended surface care products. Do not use paper towels, terry cloths, cloth
diapers or other materials with nylon fibers which can create fine scratches to surfaces.
Some painted finishes and other surfaces may be scratched if gravel, dirt or grime are
scraped across the surface during washing. Use clean towels and avoid rubbing sediments
across gloss finishes.
For repair of scratched surfaces, see a HarleyDavidson dealer.
Observe warnings on labels of cleaning compounds.
Failure to follow warnings could result in death or serious
injury. (00076a)
Do not wash brake discs with cleaners containing chlorine
or silicone. Cleaners containing chlorine and silicone can
impair brake function, which could result in death or
Do not use a pressure washer to clean motorcycle. Using a
pressure washer can result in equipment damage. (00489c)
Use of abrasive products or powered buffing equipment
will cause permanent cosmetic damage to body panels.
Use only recommended products and techniques outlined
in this manual to avoid damaging body panels. (00245b)
Recommended Cleaning and Care Products
PRODUCT PART PURPOSE FRAME BODY WHEELS DENIM OTHER
NUMBER PANELS FINISH

HD Sunwash 9465998 Thorough Yes Yes Yes Yes
Concentrate washing of all
surfaces with
a wash mitt.
Reduces hard
water spots
when washing
a motorcycle
in the sun.
HD Quick Wash 93600011 A quick wash Yes Yes Yes Yes
Cleaner (16 oz.) for a lightly
93600012 soiled
(32 oz.) motorcycle.
Cleans all
surfaces,
sheeting
action
prevents
spots.
HD Bug Remover 9465798 Removes Yes Yes Yes Yes
bugs from
metal, plastic
or painted
surfaces. Also
available as
individual
wipes (97400
10).
Harley Glaze 9970184 Polishes Yes Yes As No
Polish & Sealant windshields, applicable
painted
surfaces and
chrome.
Harley Gloss 9462798 Produces high Yes Yes Yes No
gloss with UV
protection.
Allows chrome
to breathe,
unlike wax.
Good for
windshields.
Also available
as individual
wipes (97401
10).
Harley Spray 99817 Aerosol quick Yes Yes Yes No
Cleaner and 99B cleaner and
Polish detailer.
Reduces static
attraction to
dust. Works
great for
removing
bugs.
HD Wheel and 9465898 Cleans No No Yes No
Tire Cleaner wheels, tires,
whitewalls and
blackcoated
exhaust pipes
and mufflers.
Do not use on
frames or
anodized
parts.
Harley Bright 9468399 Shines As applicable
Chrome Cleaner chromeplated
surfaces and
cleans
brushed
aluminum or
stainless steel
surfaces.
Harley Bright 9972589 Polishes non As applicable
Harley Bright 9972589 Polishes non As applicable
Metal Polish clear coated
polished
aluminum or
polished
stainless steel
surfaces.
HD Swirl & 9465598 Removes fine Yes Yes No No

Scratch Treatment scratches and
swirls.
HD Denim Paint 9486610 Waterless Yes Yes Yes Yes
Cleaner quick cleaner
and detailer.
Windshield 9740610 Quick Yes Yes No No Windshield
Cleaner Individual windshield
Wipes cleaner in
convenient
single use
wipe.
HD Black Tire 9462805 Restores No No No No Tires
Sidewall luster to black
Protectant tire sidewalls.
Harley Preserve 9984507 Corrosion As applicable
Bare Aluminum control for
Wheel Protectant bare aluminum
surfaces. Also
available as
individual
wipes (99846
10).
Windshield Water 9984101 Allows water No No No No Windshield
Repellent to bead and
Treatment dissipate from
the windshield.
Leather Dressing 98261 Weatherproofs No No No No Leather
91V and preserves goods
leather
products.
Harley 9883909 Rejuvenates No No No No Black
Rejuvenator for black leather leather
Black Leather products so goods
they look
brand new.
HD Engine 93600002 Rejuvenates No No No No Wrinkle
Brightener wrinkle black black
engine finish. engines
HD Exhaust Boot 93600001 Removes boot No No No No Exhaust
Mark Remover marks from system
chrome
exhaust
components.
Travel Care Kit 93600007 Travel size Yes Yes Yes Yes
cleaning and
care products.
Harley Seat, 93600010 Cleans and No No No No Seats,
Saddlebag and conditions saddlebags
Trim Cleaner vinyl, leather and trim
and plastic.
Use on seats,
saddlebags,
inner fairings,
and any other
trim.
NOVUS 1 99837 Cleans No No No No Windshield
Cleaner/Protectant 94T windshields,
tail lamps and
all plastics.
Resists
fingerprints,
fogging,
smears and
repels dust.
NOVUS 2 Scratch 99836 Minor scratch No No No No Windshield
Remover 94T remover for
windshields
and plastics.
Apply after
NOVUS 1.
Recommended Surface Care Products
PRODUCT PART DESCRIPTION

NO.
Wash Mitt 94760 Absorbent woolblended washing mitten.
99
Soft Detailing Pad 94790 Soft pad for removing bugs and debris without scratching the
01 surface finish.
Softstrips 94680 For cylindrical surfaces such as handlebars, forks, pushrod
99 covers and spokes.
Softcloth 94656 Nonabsorbent cloth for applying and buffing Swirl & Scratch
98 treatment and Harley Glaze to painted surfaces or chrome.
Soft Drying Towel 94791 Extraabsorbent, nonstreaking synthetic towel for drying.
01 Dampen towel and wring out before using for greatest
absorbency.
HarleyDavidson Hog 94651 Blows a stream of warm dry filtered air. Reduces streaks and
Blaster Motorcycle 09 water spots.
Dryer
Wheel & Spoke Brush 43078 Coneshaped scrub brush for wheels.
99
Microfiber Detailing 94663 Highly absorbent detailing cloth for polishing and sealing.
Cloth 02 Contains no nylon fibers.
S100 Detailing Swabs 99780 Large cotton swabs for cleaning crevices and detailed
04 surfaces.
Cleaning Brush Kit 94844 Brush kit for detailing your motorcycle.
10
HD Bike Wash Bucket 94811 Wash bucket with apron to hold your supplies. Includes grit
and Apron 10 guard.
Washing the Motorcycle
Use only recommended cleaning and care products. Refer to Recommended Cleaning and
Care Products and Recommended Surface Care Products.
NOTE:
During rinsing and washing, avoid direct spray on radio, saddlebags, trunk or TourPak
sealing areas (if equipped). Avoid spraying water under leather saddlebag covers (if
equipped).
Preparation
1. Allow motorcycle to cool before rinsing or washing. Spraying water on hot surfaces can
leave water spots and mineral deposits.
2. Rinse the motorcycle from the bottom up.
3. To loosen dried bugs or hardened dirt, allow surfaces to soak under a damp towel.
Cleaning the Wheels and Tires
1. Rinse wheel and tire surfaces. Avoid splashing brake dust on chrome or painted parts.
2. Apply WHEEL AND TIRE CLEANER. Allow cleaner to set for one minute.
3. Clean the wheel with a SOFT DETAILING PAD or WHEEL & SPOKE BRUSH. Use
SOFTSTRIPS to clean wheel spokes. Thoroughly scrub all brake dust and other sediments
off the wheel. Accumulated brake dust can trap moisture and dirt, which leads to wheel
corrosion.
4. Rinse well.
Washing the Motorcycle
NOTE:
Refer to the appropriate instructions in this section for cleaning leather, Denim (flat) finishes,
windshields or other special surfaces.
1. Fill a bucket with clean water.
2. Fill an HD WASH BUCKET with water and add HD SUNWASH CLEANER
CONCENTRATE, following the directions on the package.
3. Soak the HD WASH MITT in the SUNWASH solution. Wash all surfaces from the top
working down.
4. Spray HD BUG REMOVER to remove any bugs.
5. Rinse the motorcycle:
a. Rinse from the bottom up.
b. Rinse from the top down.
Drying the Motorcycle
1. Dry the surfaces from the top down using a SOFT DRYING TOWEL or a HARLEY
DAVIDSON HOG BLASTER MOTORCYCLE DRYER.
2. Dampen towel in clean water and wring out the excess. The towel is more absorbent when
wet.
3. Wipe across the vehicle surface.
4. Repeat as necessary until surface is completely dry.
Polishing and Sealing
NOTE:
If motorcycle has Denim finish, skip the Polishing and Sealing procedure.
1. Apply HARLEY GLAZE POLISH & SEALANT with a SOFTCLOTH or MICROFIBER
DETAILING CLOTH, following the instructions on the package.
2. Buff with a SOFTCLOTH.
3. Polish and seal the wheels as described in Wheel Care to prevent corrosion.
NOTE:
Bare aluminum wheels do not have a protective coating. The wheels corrode if not properly
treated. Apply HARLEY PRESERVE BARE ALUMINUM PROTECTANT when purchasing the
motorcycle and at least twice per year to prevent cosmetic damage to bare aluminum wheels.
Finishing Tires
Apply HARLEY BLACK to tires, following the instructions on the package.
Denim Finish Care
Some motorcycles have a Denim (flat or matte) finish. The Denim finish has qualities which differ
from high gloss finishes on all other HarleyDavidson motorcycles. Like denim fabric, Denim paint
will burnish or mar with age and use, thus adding character and personality to the finish of the
motorcycle. Refer to Recommended Cleaning and Care Products for recommended
products.
If scratched, the color coat of paint does nick/scuff and these marks cannot be rubbed out.
If polished, the finish will become less matte and more glossy over time.
How to Clean
For light deposits: Use HARLEYDAVIDSON DENIM PAINT CLEANER and a SOFTCLOTH.
This helps remove finger prints and light soil.
For heavier deposits: Use either HD SUNWASH and a clean HD WASH MITT or HD QUICK
WASH CLEANER. Rinse thoroughly with clean water.
Leather and Vinyl Care
NOTES:
Leather, vinyl and other synthetic surfaces are not designed for longterm exposure to
inclement weather and should be protected with a HarleyDavidson Seat Rain Cover or
Motorcycle Storage Cover (sold separately). See your HarleyDavidson dealer.
Many HarleyDavidson accessories and seats are made of either treated or untreated
leather or have leather inserts. Natural materials age differently and require different care
than manmade materials. Seat covers and panels made of leather will gain "character",
such as wrinkles, with age. Leather is porous and organic and each leather product will
settle into its own distinct form with use. Your leather product will mature into its own custom
shape and style from the sun, rain and time. This maturing is natural and will enhance the
custom quality of your HarleyDavidson motorcycle.
Leather, vinyl and other synthetic surfaces must be periodically cleaned and treated to maintain
its appearance and extend its life. Clean and treat these surfaces once a season or more
frequently under adverse conditions.
Do not use bleach or detergents containing bleach on
saddlebags, seats, tank panels or painted surfaces. Doing
so can result in equipment damage. (00229a)
Do not use ordinary soap to clean leather or fur. It could dry or remove the oils from the
leather.
Use HARLEY SEAT, SADDLEBAG AND TRIM CLEANER to clean leather, vinyl and other
synthetic surfaces.
Never try to dry leather quickly, using artificial means. Always let leather dry naturally, at
room temperature. Always allow leather to dry completely before using.
1. Vacuum or blow dust off.
2. Thoroughly clean leather with HARLEY SEAT, SADDLEBAG AND TRIM CLEANER,
following directions on the bottle. Allow leather to dry.
3. Once leather is dry, rejuvenate faded black leather surfaces with HARLEY REJUVENATOR
FOR BLACK LEATHER.
4. Treat with a good quality leather treatment, such as HARLEYDAVIDSON LEATHER
DRESSING.
Wheel Care
Wheels can corrode or be cosmetically damaged if they are not properly cleaned, polished and
preserved. Cleaning and sealing wheels with the proper treatment will guard against pitting,
corrosion, spots and stains. HarleyDavidson recommends that wheels be cared for weekly.
Corrosion to wheels is not considered to be a defect in materials or workmanship.
NOTE:
Bare aluminum wheels do not have a protective coating and will corrode if not properly treated.
Apply HARLEY PRESERVE BARE ALUMINUM PROTECTANT when purchasing the motorcycle
and at least twice per year to prevent cosmetic damage to bare aluminum wheels.
Keep wheels clean from harsh chemicals, acid based wheel cleaners, salt, and accumulated
brake dust. After washing wheels with WHEEL AND TIRE CLEANER, use the polish and sealing
products in Wheel Polish and Sealing Products according to the type of wheels on your
motorcycle.
Wheel Polish and Sealing Products
WHEELS PRODUCT DESCRIPTION

Bare aluminum HARLEY PRESERVE Creates a protective coating for bare aluminum
BARE ALUMINUM wheels to prevent oxidation.
PROTECTANT
Polished BRIGHT METAL Microabrasive polish to refurbish polished wheels. Do
aluminum or POLISH not use on chrome.
stainless steel HARLEY GLOSS Seals and protects against harsh chemicals, salt, and
other sediments to prevent oxidation.
Anodized (thick HARLEY GLAZE Cleans surface, removes fine scratches, and
painted POLISH & SEALANT provides a breathable sealant against acid,
surfaces) chemicals, salt, and brake dust.
Chrome BRIGHT CHROME Nonabrasive cleaner to brighten chrome wheels.
CLEANER
HARLEY GLOSS Seals and protects against harsh chemicals, salt, and
other sediments to prevent oxidation.
Windshield Care
Polycarbonate windscreens/windshields require proper
attention and care to maintain. Failure to maintain
polycarbonate properly can result in damage to the
windscreen/windshield. (00483d)
Use only HarleyDavidson recommended products on
HarleyDavidson windshields. Do not use harsh chemicals
or rain sheeting products, which can cause windshield
surface damage, such as dulling or hazing. (00231c)
Powdered, abrasive or alkaline cleanser will damage the windscreen/windshield. Ammonia
based window cleaners cause permanent yellow effects to windshields.
Do not use gas station windshield cleaner as it may damage the finish.
Do not clean in hot sun or high temperature.
Windshields require special care. HarleyDavidson recommends using WINDSHIELD CLEANER
to clean your windshield. Refer to Recommended Cleaning and Care Products for
recommended cleaning products.
NOTES:
Use NOVUS 2 SCRATCH REMOVER to remove minor scratches.
To treat the windshield with water repellent use WINDSHIELD WATER REPELLENT
TREATMENT.
Covering the windshield with a clean, wet cloth for approximately 1520 minutes before
washing will make dried bug removal easier.
1. Use mild soap and warm water to wash the windshield.
2. Wipe dry with a clean SOFT DRYING TOWEL.
NOTE:
To minimize swirl marks, cleaning should be done when motorcycle is cool and parked in the
shade. Faint swirl marks are normal and may be more visible on tinted windshields.
Big Flake Custom Paint
Big flake custom paint features a unique coating which may include flakes of varied color and
size. The surface may also have an uneven texture, as a result of multiple layers of clear coat
being applied over heavy concentrations of metallic flake. Each part will have its own distinct and
custom appearance. These are normal characteristics of the custom paint process, and do not
reflect warrantable conditions.
Troubleshooting
Troubleshooting: General
The troubleshooting section of the Owner's Manual is a
guide to diagnose problems. Read the service manual
before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00080a)
The following checklist of possible operating troubles and their probable causes will be helpful in
keeping your motorcycle in good operating condition. More than one of these conditions may be
causing trouble and should be carefully checked.
Engine
Starter Does Not Operate or Does Not Turn Engine Over
1. Engine run switch in OFF position.
2. Ignition switch not ON.
3. Discharged battery or loose or corroded connections (solenoid chatters).
4. Clutch lever not squeezed against handlebar or transmission not in neutral.
5. Jiffy stand not in retracted position (required for international models only).
6. Blown fuse.
Engine Turns Over But Does Not Start
1. Fuel tank empty.
2. Fuel filter clogged.
3. Discharged battery or loose or damaged battery terminal connections.
4. Fouled spark plugs.
5. Spark plug cable connections loose or in bad condition and shorting.
6. Loose or corroded wire or cable connection(s) at coil or battery.
7. Fuel pump inoperative.
8. Blown fuse.
Starts Hard
1. Spark plugs in bad condition, have improper gap, or are partially fouled.
2. Spark plug cables in bad condition and leaking.
3. Battery nearly discharged.
4. Loose wire or cable connection(s) at one of the battery terminals or at coil.
5. Engine oil too heavy (winter operation).
6. Fuel tank vent plugged or fuel line closed off, restricting fuel flow.
7. Water or dirt in fuel system.
8. Fuel pump inoperative.
Starts But Runs Irregularly or Misses
1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition and leaking.
3. Spark plug gap too close or too wide.
4. Battery nearly discharged.
5. Damaged wire or loose connection at battery terminals or coils.
6. Intermittent short circuit due to damaged wire insulation.
7. Water or dirt in fuel system or filter.
8. Fuel vent system plugged. See dealer.
9. One or more injectors fouled.
A Spark Plug Fouls Repeatedly
1. Incorrect spark plug.
Preignition or Detonation (Knocks or Pings)
1. Incorrect fuel.
2. Incorrect spark plug.
Overheats
1. Insufficient oil supply or oil not circulating.
2. Heavy carbon deposit from lugging engine. See dealer.
3. Insufficient air flow over cylinder heads during extended periods of idling or parade duty.
Excessive Vibration
1. Rear fork pivot shaft nuts loose. See dealer.
2. Front engine mounting bolts loose. See dealer.
3. Front chain or links tight as a result of insufficient lubrication or belt badly worn.
4. Wheels and/or tires damaged. See dealer.
5. Vehicle not properly aligned. See dealer.
Electrical System
Alternator Does Not Charge
1. Regulator not grounded. See dealer.
2. Engine ground wire loose or damaged. See dealer.
3. Loose or damaged wires in charging circuit. See dealer.
Alternator Charge Rate is Below Normal
1. Weak battery.
2. Excessive use of addon accessories.
3. Loose or corroded connections.
4. Extensive periods of idling or low speed riding.
Transmission
Transmission Shifts Hard
1. Bent shifter rod. See dealer.
Transmission Jumps Out of Gear
1. Worn shifter dogs in transmission. See dealer.
Clutch Slips
1. Clutch controls improperly adjusted. See dealer.
2. Worn friction discs. See dealer.
3. Insufficient clutch spring tension. See dealer.
Clutch Drags or Does Not Release
1. Clutch controls improperly adjusted. See dealer.
2. Primary chaincase overfilled.
3. Clutch discs warped. See dealer.
Clutch Chatters
1. Friction discs or steel discs worn or warped. See dealer.
Brakes
Brakes Do Not Hold Normally
1. Master cylinder low on fluid. See dealer.
2. Brake line contains air bubbles. See dealer.
3. Master cylinder piston worn. See dealer.
4. Brake pads contaminated with grease or oil. See dealer.
5. Brake pads badly worn. See dealer.
6. Brake disc badly worn or warped. See dealer.
7. Brake fades because of heat build up. Excessive braking or brake pads dragging. See
dealer.
8. Brake drags. Insufficient hand lever freeplay. See dealer.
Accessories
Genuine Motor Parts and Accessories
Stop at your HarleyDavidson dealer to pick up a copy of the Genuine Motor Parts and
Accessories catalog or go to www.harleydavidson.com to view thousands of Genuine Motor
Accessories that are available for HarleyDavidson motorcycles.
The website includes the following tools and resources for accessorizing and personalizing your
motorcycle.
Online Catalog
The full Genuine Motor Parts and Accessories catalog is available online in PDF format. The
catalog includes hundreds of pages of HarleyDavidson accessories and maintenance products.
For performance parts, check out the Screamin' Eagle Pro Racing Parts catalog.
Shop For Your Bike
Browse through categories of accessories and options available specifically for your motorcycle.
View product descriptions, pricing, fitment and online instruction sheets for many of the available
products.
Customizer
Virtually redesign your motorcycle with parts and accessories using the Customizer. This tool
allows you to experiment with different accessory and color combinations and shows how your
motorcycle would look with the accessories installed. You can easily create a custom list of
accessories to print out for your dealer.
Fit Shop
Learn how to customize your motorcycle to fit you personally. See how making changes to the
suspension, seat, handlebars or foot controls can enhance the ergonomics and comfort of your
motorcycle.
Custom Seats
Create a custom seat using selected designs, colors and textured materials. Custom seat
specifications can be easily printed out for your dealer.
Custom Coverage
Add Accessories To Your New Ride
HarleyDavidson is offering a limited opportunity to purchase new accessories and have them
installed at an authorized HarleyDavidson dealership and receive the Custom Coverage
extended Limited Warranty rather than the standard 90 day Parts and Accessories post purchase
overthecounter warranty.
Limited warranty for eligible street legal Genuine HarleyDavidson Motor Parts and Genuine
HarleyDavidson Motor Accessories to run concurrent with the remainder of the motorcycle's
24month manufacturer's warranty.
Visit an authorized HarleyDavidson dealership within 60 days to qualify for Custom
Coverage.
Parts and accessories must be purchased and installed at an authorized HarleyDavidson
dealership to qualify for Custom Coverage.
Visit any authorized HarleyDavidson dealership as often as you like during the 60 days
after purchase to select, purchase and install accessories.
Ride, personalize, customize. Take advantage of this Custom Coverage extended Limited
Warranty offer today to make your bike your Custom ride.
NOTE:
Customers have 60 days after the motorcycle purchase date to participate in Custom Coverage
extended Limited Warranty offer. Parts and Accessories must be purchased and installed at an
authorized HarleyDavidson dealership. Parts and Accessories purchased via the internet are not
eligible. To locate the authorized HarleyDavidson dealership nearest you, visit the Dealer Locator
on www.harleydavidson.com.
Warranties and Responsibilities
Warranty and Maintenance
This Owner's Manual contains your new motorcycle limited warranty and your owner's
maintenance record.
It is your responsibility as the owner to follow the maintenance schedule at the mileage intervals
as specified in the Owner's Manual. All of the specified maintenance services must be performed
to keep your limited warranty valid.
Some countries may require all regular maintenance and service work to be done at an
authorized HarleyDavidson dealer for your limited warranty to remain in effect. Check with your
dealer for local requirements.
1. Make an appointment with a HarleyDavidson dealer for inspection and service prior to the
first 1000 mi 1600 km , and as soon as possible after any problem arises.
2. Bring this Owner's Manual with you when you visit your authorized HarleyDavidson dealer
to have your motorcycle inspected and serviced.
3. Have the dealer technician sign the maintenance record in the Owner's Manual at the
proper mileage interval. These records should be retained by the owner as proof of proper
maintenance.
4. Keep receipts covering any parts, service or maintenance performed.
These records should be transferred to each subsequent owner.
Use only HarleyDavidson approved parts and accessories that have been designed, tested and
approved for your model and model year motorcycle.
Use of certain manufacturers' aftermarket performance parts may void all or parts of your limited
warranty. See an authorized HarleyDavidson dealer for details.
HarleyDavidson authorized dealerships are independently owned and operated and may sell
parts and accessories that are not manufactured or approved by HarleyDavidson. Therefore, you
should understand that HarleyDavidson is not and cannot be responsible for the quality,
suitability, or safety of any nonHarleyDavidson part, accessory or design modification, including
labor, which may be sold and/or installed by authorized HarleyDavidson dealerships.
Keeping It All HarleyDavidson
Genuine HarleyDavidson parts are engineered and tested specifically for use on your motorcycle.
Insist that your authorized HarleyDavidson dealer uses only genuine HarleyDavidson
replacement parts and accessories to keep your HarleyDavidson motorcycle and its limited
warranty intact.
NOTE:
Installing offroad or competition parts to enhance performance may void all or part of your new
motorcycle limited warranty. See the HarleyDavidson Motorcycle Limited Warranty in this manual
or an authorized HarleyDavidson dealer for details.
by adding too many electrical accessories. If the combined
electrical accessories operating at any one time consume
more electrical current than the vehicle's charging system
can produce, the electrical consumption can discharge the
battery and cause damage to the vehicle's electrical
system. See an authorized HarleyDavidson dealer for
advice about the amount of current consumed by
additional electrical accessories or for necessary wiring
changes. (00211c)
California and Select International Markets Evaporative Emission Controls:
2012 Models
All new 2012 HarleyDavidson motorcycles sold in the State of California and select international
markets are equipped with an evaporative emission control system. This system is designed to
meet CARB and local regulations in effect at the time of manufacture.
The system requires a small amount of maintenance. Periodic inspection is required to make sure
hoses are properly routed, not kinked or blocked and that all fittings are secure. Mounting
hardware should also be checked periodically for tightness.
EPA Noise Regulations in the United States
EPA noise regulations require that the following statements be included in the Owner's Manual.
EPA Regulations
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the
following acts or the causing thereof: (1) The removal or rendering inoperative by any person
other than for purposes of maintenance, repair, or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of
design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING:
1. Replacing the muffler(s) and/or the entire exhaust system with parts not certified to be noise
legal for street use.
2. Removing or modifying the muffler internal baffles in any way.
3. Replacing the air intake/cleaner assembly with one not certified to be noise legal for street
use.
4. Modifying the air intake/cleaner assembly in such a way as to make the vehicle no longer
noise legal for street use.
HarleyDavidson recommends that any and all noise related maintenance be done by an
authorized HarleyDavidson dealer using genuine HarleyDavidson parts.
Warranty/Service Information
Any authorized HarleyDavidson dealer is responsible for providing the warranty repair work on
your motorcycle. The fact that a dealership performs warranty repairs does not create an agency
relationship between HarleyDavidson Motor Company and the authorized dealership. If you have
any questions regarding warranty obligations contact your authorized HarleyDavidson dealer.
For normal service work or warranty work under the above conditions, you may obtain the name
and location of your nearest U.S. authorized HarleyDavidson dealer by calling 8004909635 (toll
free), in any state except Alaska and Hawaii. To find dealers worldwide, see www.harley
davidson.com.
Reporting Safety Defects in United States
Safety defects must be reported to the National Highway Traffic Safety Administration (NHTSA)
and HarleyDavidson.
NHTSA Statement
If you believe that your motorcycle has a defect which could cause a crash or could cause injury
or death, you should immediately inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying HarleyDavidson.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of motorcycles, it may order a recall and remedy campaign. However,
NHTSA cannot become involved in individual problems between you, your authorized Harley
Davidson dealer, or HarleyDavidson.
Refer to NHTSA Contacts to contact NHTSA.
NHTSA Contacts
ITEM DATA
Phone Call the Auto Safety Hot Line tollfree at 888
DASH2DOT
Mail U.S. Department of Transportation, National
Highway Traffic Safety Administration, Office of
Defects Investigation, NVS210, 400 7th Street
S.W., Washington, D.C. 20590
Web www.nhtsa.dot.gov
site
You can also obtain other information about motor vehicle safety from the hot line.
Required Documentation for Imported Motorcycles
If a HarleyDavidson motorcycle is imported into the United States, additional documentation is
required to be eligible for the United States HarleyDavidson's Limited Warranty. A Harley
Davidson dealer can provide a form explaining the requirements.
Owner Contact Information
If you move from your present address, sell your motorcycle, or purchase a preowned Harley
Davidson motorcycle, see an authorized HarleyDavidson dealer to update your owner contact
information.
This will provide HarleyDavidson with an accurate registration (as required by law in some
countries), and will allow HarleyDavidson to notify you in the event of a recall or product program.
The rights and benefits conferred upon you and the obligations of HarleyDavidson as set forth
herein are separate and distinct from any rights and duties set forth in a service contract you may
have purchased from a dealership and/or thirdparty insurance company. HarleyDavidson does
not authorize any entity to expand the warranty obligations in connection with your motorcycle or
this limited warranty.
When updating your contact information, your authorized HarleyDavidson dealer will need your
vehicle identification number (VIN), odometer mileage, and date of vehicle transfer (if applicable).
Questions and Concerns
If you have questions or concerns regarding the performance of your motorcycle or the application
of the limited warranty described here, or are not satisfied with the service you are receiving from
a HarleyDavidson dealership, do the following:
1. Contact the selling and/or servicing dealership and speak to the sales and/or service
manager.
2. If your concern cannot be addressed to your satisfaction by the dealership, contact the
HarleyDavidson Enterprise Contact Center by mailing your concern to the following address
or calling the phone number below.
State warranty laws, often referred to as lemon laws, may provide you with certain rights not
specifically mentioned here. To the extent allowed by your state, HarleyDavidson requires that
you first send written notification of any defect or warranty nonconformity that you have
experienced with your motorcycle to HarleyDavidson. HarleyDavidson appreciates the
opportunity to investigate your concerns and restore your satisfaction in your motorcycle by
making the necessary repairs. HarleyDavidson requests that you send your complaint to the
HarleyDavidson Enterprise Contact Center.
HarleyDavidson Motor Company
Attention: HarleyDavidson Enterprise Contact Center
P.O. Box 653
Milwaukee, Wisconsin 53201
(800) 2582464 (U.S. only)
(414) 3434056
Limited Motorcycle Warranty
2012 HARLEYDAVIDSON MOTORCYCLE LIMITED WARRANTY
24 Months/Unlimited Miles
HarleyDavidson warrants for any new 2012 HarleyDavidson motorcycle/sidecar that an
authorized HarleyDavidson dealer will repair or replace without charge any parts found under
normal use to be defective in factory materials or workmanship. Such repair or replacement of
parts will be HarleyDavidson's sole obligation and your sole remedy under this limited warranty.
THERE IS NO OTHER EXPRESS WARRANTY (OTHER THAN THE SEPARATE EMISSIONS
AND NOISE LIMITED WARRANTIES) ON THE MOTORCYCLE/SIDECAR. Any implied warranty
of merchantability or fitness for particular purpose is limited to the duration of the express
warranty, or to the duration set forth in your state's warranty statutes, whichever is shorter. The
implied warranty is not transferred to subsequent purchasers/buyers.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.
TO THE FULLEST EXTENT ALLOWED BY LAW, NEITHER HARLEYDAVIDSON NOR ITS
AUTHORIZED DEALERS SHALL BE LIABLE FOR LOSS OF TIME, INCONVENIENCE, LOSS
OF MOTORCYCLE/SIDECAR USE, COMMERCIAL LOSS OR OTHER INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you.
This limited warranty gives you specific legal rights, and you may have other rights which vary
from state to state.
The following terms and conditions apply to this limited warranty:
Duration
1. The duration of this limited warranty is twentyfour months, starting from the earlier of (a) the
date of initial retail purchase and delivery from an authorized HarleyDavidson dealer, or (b)
the third anniversary of the last day of the model year of the motorcycle/sidecar. Your
authorized HarleyDavidson dealer will submit an electronic Sales and Warranty
Registration form to initiate your limited warranty.
2. Any unexpired portion of this limited warranty will be transferred to subsequent owners,
upon the resale of the motorcycle/sidecar during the limited warranty period.
Owner's Obligations
To obtain warranty service, return your motorcycle/sidecar at your expense within the limited
warranty period to an authorized dealer. The authorized HarleyDavidson dealer should be able to
provide warranty service during normal business hours and as soon as possible, depending upon
the workload of the authorized dealer's service department and the availability of necessary parts.
HarleyDavidson Motor Company, P.O. Box 653, Milwaukee, Wisconsin 53201, U.S.A.
Exclusions
This limited warranty will not apply to any motorcycle/sidecar as follows:
1. Which has not been operated or maintained as specified in the Owner's Manual.
2. Which has been abused, neglected, misused, improperly stored, used "off the highway," or
used for racing or competition of any kind.
3. Which is not manufactured to comply with the laws of the market in which it is registered.
4. Which has offroad or competition parts installed to enhance performance, or has other
unapproved modifications. These modifications may void all or part of your new
motorcycle/sidecar limited warranty. See an authorized HarleyDavidson dealer for details.
5. Acts of God, war, riot, insurrection, natural disasters, including, but not limited to, nuclear
contamination, lightning, forest fires, dust storms, hail storms, ice storms, earthquakes,
floods, or for other circumstances out of HarleyDavidson's control.
6. Which has been in an accident, collision, dropped or struck.
Other Limitations
This warranty does not cover:
1. Parts and labor for normal maintenance as recommended in the Owner's Manual, or the
replacement of parts due to normal wear and tear including, but not limited to, the following:
tires, lubrication, oil and filter change, fuel system cleaning, battery maintenance, engine
tuneup, spark plugs, brake, clutch, chain/belt adjustment and chain replacement.
2. Cosmetic concerns that arise as a result of owner abuse, lack of proper maintenance or
environmental conditions (except concerns that result from defects in factory materials or
workmanship, which are covered by this limited warranty for the duration of the limited
warranty period).
3. Any cosmetic condition existing at the time of retail delivery that has not been documented
by the authorized HarleyDavidson selling dealer prior to retail delivery.
4. Defects or damage to the motorcycle/sidecar caused by alterations outside of Harley
Davidson's factory specifications.
5. Damage caused by installation or use of nonHarleyDavidson components, even those
installed by an authorized dealership, that cause a HarleyDavidson part to fail. Examples
include, but are not limited to performanceenhancing powertrain components or software,
exhaust systems, nonapproved tires, lowering kits, handlebars, addons connected to the
factory electrical system, etc.
Important: Read Carefully
1. Authorized HarleyDavidson dealers are independently owned and operated and may sell
nonHarleyDavidson products. Because of this, HARLEYDAVIDSON IS NOT
RESPONSIBLE FOR THE SAFETY, QUALITY, OR SUITABILITY OF ANY NONHARLEY
DAVIDSON PART, ACCESSORY OR DESIGN MODIFICATION INCLUDING, BUT NOT
LIMITED TO, LABOR WHICH MAY BE SOLD AND/OR INSTALLED BY AUTHORIZED
HARLEYDAVIDSON DEALERS.
2. This limited warranty is a contract between you and HarleyDavidson. It is separate and
apart from any warranty you may receive or purchase from an authorized HarleyDavidson
dealer. An authorized HarleyDavidson dealer is not authorized to alter, modify, or in any
way change the terms and conditions of this limited warranty.
3. Any warranty work or parts replacement authorized by HarleyDavidson will not preclude
HarleyDavidson from later relying on any exclusion where applicable.
Limited Noise Warranty
2012 HARLEYDAVIDSON MOTORCYCLE NOISE CONTROL SYSTEM LIMITED
WARRANTY
The following limited warranty applies to the noise control system, is in addition to the
MOTORCYCLE LIMITED WARRANTY and EMISSION CONTROL SYSTEM LIMITED
WARRANTY, and applies only to HarleyDavidson motorcycles sold in the U.S.
HarleyDavidson warrants to the first owner and each subsequent owner that this motorcycle is
designed and built so as to conform at the time of sale with applicable regulations of the U.S.
Environmental Protection Agency (as tested following F76 DriveBy test procedure) and that it is
free from defects in factory materials and workmanship which can cause this motorcycle not to
meet U.S. Environmental Protection Agency Standards within one (1) year from initial retail
purchase and delivery from an authorized HarleyDavidson dealer or one (1) year from the
[second] anniversary of the last day of the model year of the motorcycle, or 3,730 miles 6,000
kilometers whichever occurs first. Any unexpired portion of this limited warranty will be transferred
to subsequent owners, upon the resale of the motorcycle during the limited warranty period. If the
motorcycle was used as a demonstrator or company motorcycle, then the limited warranty period
may have started and/or expired prior to the initial retail sale. See an authorized HarleyDavidson
dealer for details.
THERE IS NO OTHER EXPRESS WARRANTY (OTHER THAN THE SEPARATE
MOTORCYCLE AND EMISSIONS LIMITED WARRANTIES) ON THE MOTORCYCLE. ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE IS
LIMITED TO THE DURATION OF THIS LIMITED WARRANTY.
The limited one year warranty period shall begin on the date the motorcycle is delivered to the first
retail purchaser or, if the motorcycle is placed in service as a demonstrator or company
motorcycle prior to sale at retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE NOISE CONTROL SYSTEM LIMITED
WARRANTY
1. Failures which arise as a result of misuse, alteration, or nonperformance of maintenance as
specified in the Owner's Manual.
2. Replacing, removing, or modifying any portion of the NOISE CONTROL SYSTEM
(consisting of the exhaust system and air intake/cleaner assembly) with parts not certified to
be noise legal for street use.
3. Any motorcycle on which the odometer mileage has been changed so that the mileage
cannot be determined.
4. TO THE FULLEST EXTENT ALLOWED BY LAW, NEITHER HARLEYDAVIDSON NOR
ITS AUTHORIZED DEALERS SHALL BE LIABLE FOR LOSS OF TIME, INCONVENIENCE,
LOSS OF MOTORCYCLE USE, COMMERCIAL LOSS OR OTHER INCIDENTAL OR
Other Rights
Recommendations for Required Maintenance
It is recommended that any noise system maintenance be performed by an authorized Harley
Davidson dealer using genuine HarleyDavidson replacement parts. The maintenance,
replacement or repair of the noise control system may be performed by any other qualified service
outlet or individual. Nongenuine HarleyDavidson parts may be used only if such parts are
certified to comply with U.S. Environmental Protection Agency Standards.
Limited Emission Warranty
2012 HARLEYDAVIDSON EMISSION CONTROL SYSTEM LIMITED WARRANTY
The following limited warranty applies to the emission control system, is in addition to the
MOTORCYCLE LIMITED WARRANTY and NOISE CONTROL SYSTEM LIMITED WARRANTY,
and applies only to HarleyDavidson motorcycles sold in the U.S. Refer to the "CALIFORNIA
EMISSIONS CONTROL WARRANTY STATEMENT" for additional warranty provisions applicable
to California motorcycles.
HarleyDavidson Motor Company warrants to the first owner and each subsequent owner that this
vehicle is designed, built, and equipped so as to conform at the time of sale with applicable
regulations under section 7521 of Title 42 of the United States Code, and that it is free from
defects in materials and workmanship which would cause this motorcycle to fail to conform with
applicable regulations for five (5) years from the initial retail purchase and delivery from an
authorized HarleyDavidson dealer (or five (5) years from the date the motorcycle is first placed in
service, if it is first placed in service as a "demonstrator" or "company" motorcycle prior to
delivery), or 18,641 miles 30,000 kilometers , whichever occurs first. Any unexpired portion of this
limited warranty will be transferred to subsequent owners, upon the resale of the motorcycle
during the warranty period.
THERE IS NO OTHER EXPRESS WARRANTY (OTHER THAN THE SEPARATE
MOTORCYCLE AND NOISE LIMITED WARRANTIES) ON THE MOTORCYCLE. ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE IS LIMITED
TO THE DURATION OF THIS WARRANTY.
The limited warranty period shall begin on the date the motorcycle is delivered to the first retail
purchaser or, if the motorcycle is placed in service as a demonstrator or company motorcycle
prior to sale at retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE EMISSION CONTROL SYSTEM
LIMITED WARRANTY
1. Failures which arise as a result of misuse, alterations, accident or nonperformance of
maintenance as specified in the Owner's Manual.
2. The replacement of parts (such as spark plugs, fuel and oil filters, etc.) used in required
maintenance.
3. Any motorcycle on which the odometer mileage has been changed so that the mileage
cannot be determined.
4. TO THE FULLEST EXTENT ALLOWED BY LAW, NEITHER HARLEYDAVIDSON NOR
ITS AUTHORIZED DEALERS SHALL BE LIABLE FOR LOSS OF TIME, INCONVENIENCE,
LOSS OF MOTORCYCLE USE, COMMERCIAL LOSS OR OTHER INCIDENTAL OR
Items Covered by this Emission Warranty
The emission control system warranty may cover the following parts if the defect is deemed to be
emissions related:
Intake manifold
Air cleaner backplate with solenoid operated door, as applicable
Air cleaner filter
Cam shaft
Spark plug
Ignition coil
Ignition wires
Vapor valve
Catalytic converter mufflers, as applicable
Crankcase breather
MAP sensor
Fuel Injection:
Induction module (including all sensors, injectors and all their associated connectors)
Engine temperature sensor
Barometric pressure sensor
Electronic control unit
Regulator/fuel pump (for leaks and/or high and low pressure failures)
Fuel filter
Oxygen sensors
Fuel Tank: (noncosmetic failures only)
Leaks
Fuel vapor separator
Fuel cap
If used on the above: hoses, clamps, fittings, tubing, sealing gaskets and mounting hardware
Detailed instructions for proper maintenance and use of this motorcycle, including the time and/or
mileage intervals at which such maintenance is to be performed, may be found in this Owner's
Manual under Regular Service Intervals.
Other Rights
Recommendations for Required Maintenance
It is recommended that any emission system maintenance be performed by an authorized Harley
Davidson dealer using genuine HarleyDavidson replacement parts. The maintenance,
replacement or repair of the emissions control system may be performed by any other qualified
service outlet or individual. Nongenuine HarleyDavidson parts may be used only if such parts
are certified to comply with U.S. Environmental Protection Agency Standards.
California Emissions Control Warranty
CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT
Your Warranty Rights and Obligations
The California Air Resources Board and HarleyDavidson Motor Company are pleased to explain
the emission control system warranty on your 2012 model year motorcycle. In California, new
motor vehicles must be designed, built and equipped to meet the State's stringent antismog
standards. HarleyDavidson Motor Company must warrant the emission control system on your
motorcycle for the periods of time listed below provided there has been no abuse, unapproved
modification, neglect or improper maintenance of your motorcycle.
Your emission control system may include parts such as the carburetor or fuelinjection system,
the ignition system, catalytic converter, and engine computer. Also included may be hoses,
connectors and other emissionrelated assemblies.
Where a warrantable condition exists, within the warranty period noted below, your authorized
HarleyDavidson dealer will repair your motorcycle at no cost to you including diagnosis, parts and
labor.
Manufacturer's Warranty Coverage
For a period of use of five years or 18,641 miles 30,000 kilometers , whichever first occurs,
beginning on the date the motorcycle is delivered to the ultimate purchaser:
If any emission related part on your motorcycle is defective, the part will be repaired or replaced
by HarleyDavidson Motor Company. This is your emission control system DEFECTS
WARRANTY.
Owner's Warranty Responsibilities
As the motorcycle owner, you are responsible for the performance of the required maintenance
listed in your Owner's Manual. HarleyDavidson recommends that you retain all receipts covering
maintenance on your motorcycle, but HarleyDavidson cannot deny emissions warranty coverage
solely for the lack of receipts or for your failure to ensure the performance of all scheduled
maintenance.
You are responsible for presenting your motorcycle to an authorized HarleyDavidson dealer as
soon as a problem exists. The warranty repairs should be completed in a reasonable amount of
time, not to exceed 30 days.
As the motorcycle owner, you should also be aware that HarleyDavidson may deny you warranty
coverage if your motorcycle or a part has failed due to abuse, neglect, improper maintenance or
unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you should contact
HarleyDavidson Customer Service Department at (800) 2582464 (U.S. only) or (414) 3434056,
or the California Air Resources Board at 9528 Telstar Ave., El Monte, California 91731.
Additional Warranty Terms
The warranty period starts the date the motorcycle is delivered to the ultimate purchaser or, if the
motorcycle is placed in service as a demonstrator or company motorcycle prior to sale at retail,
the date it is first placed in service.
The emission control system of each new HarleyDavidson® motorcycle was designed, built and
tested using only Genuine HarleyDavidson parts and with these parts the motorcycle is certified
as being in conformity with California emission control regulations.
We recommend that you take your motorcycle to an authorized HarleyDavidson dealer for repairs
under this warranty. The dealer has factorytrained mechanics and genuine HarleyDavidson
parts. However, in the case of an "emergency" (as defined below), you could have repairs
performed at any available service establishment or by the owner, using any replacement part. An
authorized HarleyDavidson dealer not being reasonably available, or a part not being available
within a reasonable time period (not to exceed 30 days from the time the motorcycle is initially
presented to a HarleyDavidson dealer for repair) constitutes an emergency. HarleyDavidson will
reimburse the owner for such repairs, including diagnosis, only if it is established that the repairs
are covered under this emission warranty. HarleyDavidson's parts reimbursement, however, will
not exceed our suggested retail price for all warranted parts replaced and our labor
reimbursement will be limited to our recommended time allowances for emission system repairs at
the geographically appropriate hourly labor rate.
To obtain reimbursement from HarleyDavidson for such emergency repairs, you must keep all
failed parts and original receipts, so you can present them to an authorized HarleyDavidson
dealer for inspection. HarleyDavidson recommends that you bring your motorcycle to an
authorized dealer for inspection to ensure that the emergency repairs were done properly.
Remember: Use of replacement parts which are not equal in quality to Genuine HarleyDavidson
parts may impair the effectiveness of the emission control system or otherwise damage your
motorcycle. If other than genuine HarleyDavidson parts are used for maintenance, replacement
or repair of components affecting emission control, you should obtain written assurances that
such nonHarleyDavidson parts are warranted by their manufacturer to be equal in quality to
Genuine HarleyDavidson parts in both performance and durability. The use of nonHarley
Davidson replacement parts does not invalidate the existing warranty, if any, on other Harley
Davidson components unless the nonHarleyDavidson parts cause damage to warranted parts or
result in the creation of an emissions noncompliant motorcycle. However, HARLEYDAVIDSON
ASSUMES NO LIABILITY UNDER THIS WARRANTY WITH RESPECT TO ANY PARTS WHICH
ARE NOT GENUINE HARLEYDAVIDSON PARTS, unless HarleyDavidson parts cause damage
to nongenuine HarleyDavidson parts.
What Is Covered By This Emission Warranty
The emission control system warranty covers the following "warranted parts" only:
Intake manifold
Air cleaner backplate with solenoid operated door, as applicable
Air cleaner filter
Cam shaft
Spark plug
Ignition coil
Ignition wires
Charcoal canister
Vapor valve
Catalytic converter mufflers, as applicable
Crankcase breather
Purge control valves
MAP sensor
Fuel Injection:
Induction module (including all sensors, injectors and all their associated connectors)
Engine temperature sensor
Electronic control unit
Regulator/fuel pump (for leaks and/or high and low pressure failures)
Fuel filter
Oxygen sensors
Fuel Tank: (noncosmetic failures only)
Leaks
Fuel vapor separator
Fuel cap
If used on the above: hoses, clamps, fittings, tubing, sealing gaskets and mounting hardware
What Is Not Covered By This Emission Warranty
The emission control system warranty does not cover:
Malfunctions in any "warranted parts" caused by any of the following: abuse, misuse, unapproved
modification or alteration, tampering, disconnection, or improper or inadequate maintenance. The
warranty also does not cover replacement of listed parts in the event that the vehicle has been
rendered emissions noncompliant in the state of California through actions noted above.
Damage resulting from accident, acts of nature or other events beyond the control of Harley
Davidson.
The repair or replacement of "warranted parts" which are scheduled for replacement prior to
18,641 mi 30,000 km , once these parts have been replaced at the first replacement interval as
part of required maintenance services.
Repairs and services performed by anyone other than an authorized HarleyDavidson Dealer
(except in case of emergency as defined above).
Loss of time, inconvenience, loss of use of the motorcycle, towing of the vehicle, or commercial
loss and/or consequential damages.
Repairs on any motorcycle of which odometer mileage has been changed so that mileage cannot
be readily determined.
Maintenance Scheduling
Regular Service Intervals
Refer to Regular Service Intervals: 2012 Sportster Models. Regular maintenance must be
performed at specified intervals to help keep your new HarleyDavidson motorcycle operating at
peak performance and keep your new motorcycle limited warranty in force. Your HarleyDavidson
dealer knows best how to service your motorcycle with factory approved methods and equipment
assuring you of thorough and competent workmanship.
Some maintenance items should be done at least once per year as specified, even if the next
mileage interval has not been reached. In severe riding conditions, some maintenance items may
need to be performed more frequently. Refer to the notes in Regular Service Intervals: 2012
Sportster Models.
NOTES:
The use of parts and service procedures other than HarleyDavidson approved parts and
service procedures may void the warranty. Any alterations to the emission system
components, such as the intake and exhaust system, may be in violation of motor vehicle
laws.
Some countries, such as Brazil, may require all regular maintenance to be performed by an
authorized HarleyDavidson dealer for your limited warranty to remain in effect. Check with
your authorized HarleyDavidson dealer.
Some countries, such as Brazil, may require additional annual (or semiannual) regular
maintenance steps to be performed to keep your limited warranty in effect and/or comply
with vehicle regulations. Check with your authorized HarleyDavidson dealer and check the
motorcycle regulations in your country for local requirements.
After completing the final service interval in Regular Service Intervals: 2012 Sportster
Models, repeat the service schedule starting at the 5000 mi 8000 km interval.
If you operate your motorcycle under adverse conditions
(severe cold, extreme heat, very dusty environment, very
bad roads, through standing water, etc.), you should
perform the regular maintenance intervals more frequently
to ensure the safe operation of your motorcycle. Failure to
maintain your motorcycle could result in death or serious
injury. (00094a)
Regular Service Intervals: 2012 Sportster Models
ITEM PROCEDURE 1000 5000 10,000 15,000 20,000 25,000 30,000 NOTES
SERVICED MI MI MI MI MI MI MI
1600 8000 16,000 24,000 32,000 40,000 48,000

KM KM KM KM KM KM KM
Engine oil Replace X X X X X X X 3, 7
and filter
Oil lines and Inspect for leaks, X X X X X X X 1, 3
brake system contact or abrasion
Air cleaner Inspect, service as X X X X X X 7
required
Tires Check pressure, X X X X X X X 3
inspect tread
Wheel Check tightness X X X 1, 5, 7
spokes (if
equipped)
Primary Check adjustment X X X X X X X
chain
Transmission Replace X X X X 7
lubricant
Clutch Check adjustment X X X X X X X 1, 7
Drive belt Inspect, adjust belt X X X X X X X 1
and
sprockets
Throttle, Check, adjust and X X X X X X X 1
brake and lubricate
clutch
controls
Jiffy stand Inspect and lubricate X X X X X X X 1
Fuel lines Inspect for leaks, X X X X X X X 1, 3
and fittings contact or abrasion
Fuel filter Replace Replace every 100,000 mi 160,000 km . 1
element
Brake fluid Inspect sight glass X X X X X X X 4
Brake fluid Inspect sight glass X X X X X X X 4
Brake pads Inspect for wear X X X X X X X
and discs
Front brake Inspect X X X X X 1, 6
lever pin
Front brake Lubricate X 1, 6
lever pin
Brake caliper Inspect X X X X X 1, 6
pins
Brake caliper Lubricate X 1, 6
pins
Brake caliper Inspect X X X X X 1, 6
boots and
bushings
Brake caliper Replace X 1, 6
boots and
bushings
Rear master Inspect X X X X X X 1, 6
cylinder
outer boot
Brake Replace brake rubber X 1, 6
components components in master
cylinders and calipers
Brake Lubricate master X 1, 6
components cylinder pistons
Spark plugs Replace X 8
Electrical Check operation X X X X X X X
equipment
and switches
Front fork oil Replace fork oil and inspect every 50,000 mi 1
80,000 km
Steering Adjust X X 1, 2
head
bearings
Rear fork Inspect every 30,000 mi 48,000 km 1
bearings
Critical Check tightness X X X X 1
fasteners
Engine Inspect X X X 1
mounts and
stabilizer
links
Battery Check battery and clean connections annually.
Exhaust Inspect for leaks, X X X X X X X 3, 7
system cracks, and loose or
missing fasteners or
heat shields
Road test Verify component and X X X X X X X
system functions
NOTES: 1. Should be performed by an authorized HarleyDavidson dealer, unless you
have the proper tools, service data and are mechanically qualified.
2. Disassemble, lubricate and inspect every 30,000 mi 48,000 km .
3. Perform annually or at specified intervals, whichever comes first.
4. Replace DOT 4 hydraulic brake fluid and flush system every two (2) years.
5. Perform spoke tension check at 1000 mi 1600 km , 5000 mi 8000 km , 20,000
mi 32,000 km services and every 15,000 mi 24,000 km interval thereafter. Not all
vehicles are equipped with spoke wheels. Consult appropriate topic in service
manual.
6. Replace every four (4) years or at specified intervals, whichever comes first.
7. Perform maintenance more frequently in severe riding conditions (such as
extreme temperatures, dusty environments, mountainous or rough roads, long
storage conditions, short runs, heavy stop/go traffic or poor fuel quality).
8. Replace every two (2) years or at specified intervals, whichever comes first.
Owner's Maintenance Records
SERVICE MILE INTERVAL DATE DEALER TECHNICIAN TECHNICIAN
NUMBER NAME SIGNATURE

1000 mi 1600 km
5000 mi 8000 km
10,000 mi 16,000 km
15,000 mi 24,000 km
20,000 mi 32,000 km
25,000 mi 40,000 km
30,000 mi 48,000 km
35,000 mi 56,000 km
40,000 mi 64,000 km
45,000 mi 72,000 km
50,000 mi 80,000 km
Service Literature
Refer to Service Literature: 2012 Sportster Models. Visit any HarleyDavidson dealer or go
to www.harleydavidson.com to purchase a service or parts manual for your motorcycle. Factory
authorized manuals are the most complete and detailed source of information outside of your
HarleyDavidson dealer.
Service Literature: 2012 Sportster Models
DOCUMENT LANGUAGE PART NUMBER

Service Manual English 9948412A
Brazilian Portuguese 9948412BRA
French 9948412FRA
German 9948412DEA
Spanish 9948412ESA
Italian 9948412ITA
Simplified Chinese 9948412ZHA
Electrical Diagnostic Manual English 9949512
Brazillian Portuguese 9949512BR
French 9949512FR
German 99495121DE
Spanish 9949512ES
Italian 9949512IT
Simplified Chinese 9949512ZH
Parts Catalog English 9945112A
HD 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, HD, HDnet.com, Harley, HarleyDavidson, 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, TechLink, TechLink II, TourPak, 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, VRod, VRSC and HarleyDavidson Genuine Motor Parts and Genuine Motor
Accessories are among the trademarks of HD Michigan, Inc.
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 ThreadSetter Tool Kit, MAXI fuse, Molex,
Michelin, MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex, Philips, PJ1, Pozidriv,
Robinair, S100, Sems, Snapon, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco,
Ultratorch, Velcro, XActo, XM Satellite Radio, and zumo are among the trademarks of their
respective owners.

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2012 IRON 883 ­ Owner's Manual

POSITION DESCRIPTION POSSIBLE VALUES

CODE MODEL NAME CODE MODEL NAME

LABEL* PART DESCRIPTION LOCATION

ITEM XL 883 MODELS XL 1200 MODELS XR 1200X

DRIVE ITEM NUMBER OF TEETH

GEAR XL 883 MODELS XL 1200 MODELS XR 1200X

ITEM XL 883R XL 883L XL 883N

ITEM XL 1200C XL 1200N XL 1200X XL 1200V XR 1200X

ITEM XL 883L XL 883R XL 883N

ITEM XL 1200C XL 1200N XL 1200X XL 1200V XR 1200X

ITEM XL 883R XL 883L XL 883N

ITEM XL 1200C XL 1200N XL 1200X/V XR 1200X

LAMP DESCRIPTION BULBS CURRENT HARLEY­

MODEL MOUNT DIAMETER SPECIFIED TIRE PRESSURE (cold)

XL 1200N rear 16 Michelin Scorcher "31" 150/80B16 40 276

STEP ACTION WAIT FOR CONFIRMATION NOTES

STEP ACTION WAIT FOR CONFIRMATION NOTES

GEAR CHANGE mph km/h

TYPE VISCOSITY RATING LOWEST COLD WEATHER STARTS

PRODUCT PART PURPOSE FRAME BODY WHEELS DENIM OTHER

NUMBER PANELS FINISH

H­D Swirl & 94655­98 Removes fine Yes Yes No No

PRODUCT PART DESCRIPTION

WHEELS PRODUCT DESCRIPTION

1600 8000 16,000 24,000 32,000 40,000 48,000

SERVICE MILE INTERVAL DATE DEALER TECHNICIAN TECHNICIAN

NUMBER NAME SIGNATURE

DOCUMENT LANGUAGE PART NUMBER

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2012 IRON 883 Owner's Manual

LAMP DESCRIPTION BULBS CURRENT HARLEY

HD Swirl & 9465598 Removes fine Yes Yes No No