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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 observe the rules contained in the RIDING TIPS booklet accompanying this Owner's Manual. Read and familiarize yourself with the contents of the MOTORCYCLE HANDBOOK for your state. Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls, correct fuel and oil supply.
Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)
Use only Harley Davidson 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.
2010 XR1200 Owner's Manual
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 death or serious injury. (00007a)
A new motorcycle must be operated according to the special break in procedure. See Break in 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 800 446 9227 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.
regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)
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 serious injury. (00011a)
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 Harley Davidson replacement fasteners. Aftermarket fasteners can adversely affect performance, which could result in death or serious injury. (00013a)
See your Harley Davidson 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 and have adequate tread. Inspect your tires regularly and see a Harley Davidson dealer for replacements. Riding with excessively worn, unbalanced or under inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)
Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley Davidson 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 result in death or serious injury. (00015a)
Do not exceed the motorcycle's Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR). Exceeding these weight ratings can affect stability and handling, which could result in death or serious injury. (00016e)
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 plate, 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.
Do not tow a disabled motorcycle. Towing can adversely affect stability and handling, which could result in death or serious injury. (00017a)
Do not pull a trailer with a motorcycle. Pulling a trailer can cause tire overload, reduced braking efficiency and adversely affect stability and handling, which could result in death or serious injury. (00018b)
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 known to the State of California to cause cancer, and birth 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 Harley Davidson 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 could result in death or serious injury. (00020a)
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
adversely affect stability and handling, which could result in death or serious injury. (00018b)
Accessory and Cargo Guidelines
The following guidelines should be used when equipping a motorcycle, carrying passengers and/or cargo.
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. 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, back rests, and luggage racks can adversely affect handling. Only genuine Harley Davidson items designed specifically for the motorcycle model should be used with proper installation.
Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)
Only Touring Harley Davidson Motorcycles are suitable for sidecar use. Consult a Harley Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a)
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 Harley Davidson VIN: 2010 Sportster Models. A unique 17 digit serial or Vehicle Identification Number (VIN) is assigned to each motorcycle. Refer to Harley Davidson VIN Breakdown: 2010 Sportster Models.
Location
See VIN Locations: Sportster Models. The full 17 digit 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 17 digit Vehicle Identification Number when ordering parts or making any inquiry about your motorcycle.
6=Evolution®^ 1200 cm^3 precision cooled, fuel injected 6 Introduction date/calibration
Normal Introduction
1=Domestic
3=California
A=Canada
C=HDI
E=Japan
G=Australia
J=Brazil
Mid year or Special Introduction
2, 4=Domestic
5, 6=California
B=Canada
D=HDI
F=Japan
H=Australia
K=Brazil 7 VIN check digit Can be 0 9 or X 8 Model year A= 9 Assembly plant C=Kansas City, MO U.S.A. 10 Sequential number Varies
VIN Model Codes: 2010 Sportster Models
CODE MODEL CODE MODEL CP (^) XL 883C Sportster® (^) 883 Custom CX (^) XL 1200L Sportster® (^) 1200 Low
CR (^) XL 883L Sportster®^ 883 Low CZ (^) XL 1200N Nightster®
CS (^) XL 883R Sportster®^ 883R LC (^) XL 1200X Forty Eight™
LE (^) XL 883N Iron 883® LA (^) Sportster® (^) XR 1200™
CT (^) XL 1200C Sportster®^ 1200 Custom LD (^) Sportster®^ XR 1200X™
Some models 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 for label descriptions.
NOTE:
Some labels may be available in different languages for destinations outside the U.S. See a Harley Davidson dealer for all labels available for purchase.
Labels
LABEL PART NUMBER
DESCRIPTION LOCATION
1 15368 01A Battery warning Top of belt guard (XR models)
Left side of swingarm (XL models) 2 Not sold separately
Shock absorber label (XR 1200X) Rear of shock absorber reservoir
3 29147 07 General warnings (XL 883R, XL 883N, XL 1200N, XL 1200X)
Top of air cleaner cover
29127 95B General warnings (other XL models) Top of air cleaner cover 29466 08 General warnings (XR models) Top of left side cover 4 15376 06 Battery removal/installation Inside left side cover
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 1200 MODELS Number of cylinders 2 Type 4 cycle, 45 degree, V twin, air cooled Compression ratio 8.9 1 9.7 1 10.0 1 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 (^) 53.89 in^3 883.10 cm^3 73.40 in^3 1202.81 cm^3 73.40 in^3 1202.81 cm
Torque (North America) 55.00 ft lbs
@ 3500 rpm
74.58 Nm
@ 3500 rpm
79.00 ft lbs
@ 4000 rpm
107.12 Nm
@ 4000 rpm
73.91 ft lbs
@ 4000 rpm
100.21 Nm
@ 4000 rpm Torque (World) 51.29 ft lbs 69.55 Nm 72.26 ft lbs 97.98 Nm 72.43 ft lbs 98.22 Nm
Overall Gear Ratios
GEAR XL 883 MODELS XL 1200 MODELS XR 1200 MODELS ALL
MODELS
U.S.
MODELS
WORLD
MODELS
U.S./WORLD
MODELS
JAPAN
MODELS
1st 10.782 9.315 9.004 10.782 9.
2nd 7.702 6.653 6.432 7.702 6.
3rd 5.728 4.948 4.783 5.728 5.
4th 4.748 4.102 3.965 4.748 4.
5th 4.071 3.517 3.400 4.071 3.
Tires
MODEL MOUNT DIAMETER (in) NUMBER PRESSURE (COLD) psi kPa
XL 883C, XL 1200C front 21 Dunlop D402F MH90 21 30 206
XL 1200X front 16 Dunlop D402F MT90B16 36 248
Other XL models front 19 Dunlop D401F 100/90 19 30 206
XL all models rear 16 Dunlop D401 150/80B16 40 275
XR models front 18 Dunlop D209F RP 120/70 ZR 18 36 248
XR models rear 17 Dunlop D209 HD 180/55 ZR 17 42 290
Dimensions: 883 Models
ITEM XL 883R XL 883C XL 883L XL 883N in mm in mm in mm in mm
Wheel base 60.00 1524.00 60.40 1534.16 60.00 1524.00 60.00 1524.
Overall length 90.10 2288.54 90.30 2293.62 89.10 2263.14 85.80 2179.
Overall width 32.70 830.58 32.70 830.58 35.20 894.08 32.32 821.
Road clearance 5.60 142.24 4.40 111.76 3.90 99.06 3.90 99.
Overall height 44.80 1137.90 45.70 1160.78 45.70 1160.78 43.60 1107.
Saddle height* 27.30 693.42 26.50 673.10 25.30 642.62 25.30 642.
*With 180 lb 81.7 kg rider on seat.
Dimensions: 1200 Models
ITEM XL 1200C XL 1200L XL 1200N XL 1200X XR 1200 XR 1200X in mm in mm in mm in mm in mm in mm
Wheel base 60.40 1534.16 59.70 1516.38 60.00 1524.00 59.80 1518.92 59.80 1518.92 59.80 1518.
Overall length 90.30 2293.62 89.10 2263.14 85.80 2179.32 88.60 2250.44 85.40 2169.16 85.40 2169.
Overall width 32.70 830.58 35.20 894.08 36.40 924.56 32.70 830.58 36.50 927.10 36.50 927.
Road clearance
Overall height 45.70 1160.78 46.80 1188.72 43.60 1107.44 42.00 1066.80 45.10 1145.54 45.10 1145.
Saddle height* 26.50 673.10 26.30 668.02 25.30 642.62 26.00 660.4 29.20 741.68 29.20 741.
Saddle height* 26.50 673.10 26.30 668.02 25.30 642.62 26.00 660.4 29.20 741.68 29.20 741.
*With 180 lb 81.7 kg rider on seat.
Capacities
ITEM XL 883C, XL 1200C
XL 1200L
XL 883L, XL 883N
XL 883R, XL
1200N
XL 1200X XR 1200, XR 1200X
U.S. LITERS U.S. LITERS U.S. LITERS U.S. LITERS
Fuel tank (total) 4.50 gal 17.03 3.30 gal 12.49 2. gal
7.95 3.50 gal 13.
Oil tank with filter 2.80 qt 2.65 2.80 qt 2.65 2.80 qt 2.65 2.80 qt 2.
Transmission (approximate)
1.00 qt 0.95 1.00 qt 0.95 1.00 qt 0.95 1.00 qt 0.
Low fuel warning light on 1.00 gal 3.79 0.80 gal 3.03 0. gal
2.46 0.50 gal 1.
Weights: 883 Models
ITEM XL 883C XL 883L XL 883R XL 883N lb kg lb kg lb kg lb kg
Weight (as shipped from factory) 565.00 256.28 563.00 255.37 568.00 257.64 548.00 248.
GVWR 1000.00 453.59 1000.00 453.59 1000.00 453.59 1000.00 453.
GAWR front 335.00 151.95 335.00 151.95 335.00 151.95 335.00 151.
GAWR rear 665.00 301.64 665.00 301.64 665.00 301.64 665.00 301.
Weights: 1200 Models
ITEM XL 1200C XL 1200L XL 1200N XL 1200X XR 1200 XR 1200X lb kg lb kg lb kg lb kg lb kg lb kg
Weight (as shipped from factory)
GVWR 1000.00 453.59 1000.00 453.59 1000.00 453.59 1000.00 453.59 1000.00 453.59 1000.00 453.
GAWR
front
GAWR
rear
Bulb Chart
LAMP DESCRIPTION
(ALL LAMPS 12 V)
BULBS
REQUIRED
CURRENT
DRAW
(AMPERAGE)
HARLEY
DAVIDSON
PART NUMBER
Headlamp High beam/low beam 1 5.0/4.58 68329 03
Position lamp international 1 0.32 53436 97
Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00026a)
Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)
Harley Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Harley Davidson approved replacement tires. (00090b)
See Specifications for tire pressures and sizes.
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 containing METHYL TERTIARY BUTYL ETHER (MTBE): Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. Gasoline/MTBE blends can be used in your motorcycle. ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%. REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline, leaving fewer tailpipe emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and Harley Davidson recommends you use it when possible, as an aid to cleaner air in our environment. Do not use race gas or octane boosters. Use of these fuels will damage the fuel system.
Some gasoline blends might adversely affect the starting, driveability or fuel efficiency of the motorcycle. 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 result in death or serious injury. (00028a)
Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00029a)
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
All international (HDI) and destination Japan model motorcycles are equipped with catalytic converters.
Do not operate catalytic converter equipped 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 converter equipped 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 serious injury. (00043a)
Some features explained are unique to certain models. These features may be available as accessories for your Harley Davidson motorcycle. See a Harley Davidson dealer for a complete list of accessories that will fit your specific motorcycle.
- Ignition off
- Accessory ON (ACC.)
- Ignition ON Ignition/Headlamp Key Switch: Sportster Models
Ignition/Headlamp Key Switch
SWITCH POSITION
FUNCTION
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 have an additional function position lamp and tail lamp are also on.
Hand Controls: Basic Operation
Electric Starter Switch
NOTE:
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.
- Put the engine off/run switch in the RUN position and the transmission in neutral. Neutral (green) indicator lamp should be illuminated.
- See Ignition/Headlamp Key Switch: Sportster Models. Turn ignition/headlamp key 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.
- To shut the engine off, push the top of the off/run switch to the ignition OFF position.
- See Ignition/Headlamp Key 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 spring loaded throttle friction adjustment screw (10) is located at the bottom of the throttle grip clamp on non cruise equipped models.
- Slowly turn throttle control grip clockwise (toward the front of the motorcycle) to close the throttle (decelerate).
- 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. Over tightening can lead to loss of vehicle control, which could result in death or serious injury. (00031b)
- Loosen the throttle friction adjustment screw so the throttle returns to the idle position when the hand is removed from the grip.
- 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, which could result in death or serious injury. (00032a)
See Handlebar Controls. The clutch hand lever (1) is located on the left handlebar and is operated with the fingers of the left hand.
