1987 Sportster 1200 Manual PDF

The 1987 Harley-Davidson Sportster 1200 is a classic American motorcycle featuring a 1200cc V-twin engine, 4-speed transmission, chain drive, and iconic cruiser styling. This manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for the XLH 1200 model. Below are key sections for safety, features, maintenance, specifications, operation, and troubleshooting.

1. Features at a Glance 2. Safety Information 3. Maintenance Schedule 4. Specifications 5. Controls and Operation 6. Engine Maintenance 7. Electrical System 8. Brake System 9. Troubleshooting 10. Warranty Information

Features at a Glance

Key components: 1200cc Evolution V-twin engine, 4-speed transmission, chain final drive, dual seat, forward controls, and classic cruiser styling.

Feature	Description
Engine	1200cc air-cooled V-twin Evolution engine
Transmission	4-speed constant mesh
Final Drive	Chain drive
Frame	Steel tubular frame
Suspension	Front telescopic fork, rear dual shocks
Brakes	Front disc brake, rear drum brake
Fuel Capacity	2.25 gallons
Seat Height	27.5 inches
Weight	489 lbs (dry)
Color Options	Black, two-tone schemes

Safety Information

Always wear proper protective gear and follow safety procedures when operating or maintaining your Sportster.

Wear helmet, eye protection, gloves, and protective clothing
Check motorcycle condition before each ride
Follow all traffic laws and regulations
Never operate under influence of alcohol or drugs
Complete proper break-in procedure for new engine

WARNING! Motorcycles are inherently dangerous; ride responsibly and within your skill level. Always perform maintenance with engine off and cool.

Maintenance Schedule

Regular maintenance is essential for optimal performance and safety.

Pre-ride inspection: Check tires, brakes, lights, fuel, oil
Every 500 miles: Check chain tension and lubricate
Every 2,500 miles: Change engine oil and filter
Every 5,000 miles: Check valve clearances
Every 10,000 miles: Replace spark plugs
Annual: Check brake fluid, replace if necessary

CAUTION! Use only Harley-Davidson recommended fluids and parts. Keep records of all maintenance performed.

Specifications

Engine Type: 4-stroke, 45° V-twin
Displacement: 1200cc (73.2 cu in)
Bore x Stroke: 3.5" x 3.812"
Compression Ratio: 9:1
Fuel System: Keihin constant velocity carburetor
Ignition: Electronic breakerless
Transmission: 4-speed, constant mesh
Final Drive: Chain, 57/24 ratio
Wheelbase: 60.2 inches
Fuel Capacity: 2.25 gallons

Controls and Operation

Familiarize yourself with all controls before operating the motorcycle.

Left Handlebar: Clutch lever, horn button, turn signal switch, high/low beam switch

Right Handlebar: Front brake lever, throttle grip, engine kill switch, starter button

Instrument Cluster: Speedometer, odometer, neutral indicator, high beam indicator, turn signal indicators

Foot Controls: Gear shift lever (left), rear brake pedal (right)

Engine Maintenance

Proper engine maintenance ensures longevity and performance.

Oil Change: Drain oil when warm, replace filter, refill with 3 quarts
Air Filter: Clean foam element in solvent, re-oil with proper air filter oil
Spark Plugs: Replace with Champion N4C or equivalent, gap at 0.035"
Valve Adjustment: Check clearance every 5,000 miles, adjust if necessary
Carburetor: Clean and adjust as needed for optimal performance

Tip: Always warm up engine before riding and allow to cool before performing maintenance.

Electrical System

12-volt electrical system with battery, alternator, and standard lighting.

Battery: 12V, maintain proper fluid level, keep terminals clean
Charging System: Alternator output 19 amps at 2000 RPM
Lights: Check operation of headlight, taillight, brake light, turn signals
Fuses: Located under seat, carry spare fuses
Wiring: Inspect regularly for damage or corrosion

WARNING! Disconnect battery before performing electrical work to prevent shorts or shocks.

Brake System

Front disc brake and rear drum brake require regular inspection and maintenance.

Front Brake: Single disc with hydraulic caliper, check pad wear
Rear Brake: Mechanical drum brake, adjust cable as needed
Brake Fluid: Check level in front master cylinder, replace every 2 years
Brake Lines: Inspect for cracks or leaks
Brake Operation: Test brakes before each ride

CAUTION! Worn brakes can cause accidents. Replace brake components at first sign of wear.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel level, spark plugs, battery charge
Poor performance	Dirty air filter, carburetor issues	Clean air filter, check carburetor adjustment
Electrical problems	Battery, connections, or alternator	Test battery, clean connections, check charging system
Brake issues	Worn pads, low fluid, adjustment	Inspect brake components, adjust or replace as needed
Chain problems	Loose tension, lack of lubrication	Adjust chain tension, clean and lubricate

Service: Contact authorized Harley-Davidson dealer for complex repairs

Parts: Use genuine Harley-Davidson parts for best performance

Warranty Information

1987 Harley-Davidson Sportster 1200 came with 12-month unlimited mileage warranty. Contact Harley-Davidson for specific warranty details and coverage.

For technical support and parts information, contact Harley-Davidson Customer Service or visit authorized dealership.