Specifications of engine (Harley Sportster XL1200)

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Table 3-1. Engine

ITEM	XL 883 MODELS		XL 1200 MODELS		XR1200X
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	53.9 in3	883 cm³	73.4 in3	1202 cm³	73.4 in3	1202 cm³

Table 3-2. Cylinder heads: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Valve guide in head (tight)	0.0033-0.0020	0.084-0.051	-	-
Valve seat in head	0.0035-0.0010	0.089-0.025	-	-
Head gasket surface (flatness)	0.006	0.152	Replace if more than 0.006	Replace if more than 0.152

Table 3-3. Rocker arms and shafts: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Shaft in bushing (loose)	0.0005-0.0020	0.013-0.051	0.0035	0.0889
End clearance	0.003-0.013	0.08-0.33	0.025	0.635
Bushing fit in rocker arm	0.004-0.002	0.10-0.05	-	-
Shaft fit in rocker cover	0.0007-0.0022	0.018-0.056	0.0035	0.0889

Table 3-4. Valves-883 cc/1200 cc

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Fit in guide (intake/exhaust)	0.001-0.003	0.0254-0.0762	0.0038	0.0965
Seat width	0.040-0.062	1.02-1.57	0.090	2.286
Stem protrusion from cylinder valve pocket	2.028-2.064	51.511-52.426	2.082	52.883

Table 3-5. Valve springs (intake/exhaust): all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
Closed	135 lbs @ 1.850 in	61.2 kg @ 47.0 mm	-	-
Open	312 lbs @ 1.300 in	141.5 kg @ 33.0 mm	-	-
Free length	2.325 in	59.1 mm	2.325 in (min)	59.1 mm (min)

Table 3-6. Tappets: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Fit in guide	0.0008-0.0023	0.020-0.058	0.003	0.0762
Roller fit	0.0006-0.0013	0.015-0.033	-	-
Roller end clearance	0.008-0.022	0.203-0.559	0.026	0.660

Table 3-7. Cylinder bore: XL 883 Models

BORE DIAMETER	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Standard +/-0.0002 in (0.0051 mm)	3.0005	76.213	3.0035	76.289
0.005 in OS +/-0.0002 in (0.0051 mm)	3.0048	76.323	3.0078	76.389
0.010 in OS +/-0.0002 in (0.0051 mm)	3.0098	76.449	3.0128	76.525
Taper	-	-	0.002	0.0508
Out of round	-	-	0.003	0.0762
Top gasket surface warpage	-	-	0.006	0.152
Base gasket surface warpage	-	-	0.008	0.203

Table 3-8. Cylinder bore: all 1200 models*

BORE DIAMETER	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Standard +/-0.0002 in (0.0051 mm)	3.4978	88.844	3.5008	88.920
0.005 in OS +/-0.0002 in (0.0051 mm)	3.502	88.95	3.505	89.027
0.010 in OS +/-0.0002 in (0.0051 mm)	3.507	89.08	3.510	89.154
Taper	-	-	0.002	0.0508
Out of round	-	-	0.003	0.0762
Top gasket surface warpage	-	-	0.006	0.152
Base gasket surface warpage	-	-	0.008	0.203

* XR 1200X: Oversized pistons are not available. Replace piston and/or cylinder as needed.

Table 3-9. Pistons: XL 883 models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Compression ring gap (top and 2nd)	0.010-0.023	0.25-0.58	0.032	0.813
Oil control ring rail gap	0.010-0.053	0.25-1.35	0.065	1.651
Top compression ring side clearance	0.0020-0.0045	0.051-0.114	0.0065	0.165
2nd compression ring side clearance	0.0020-0.0045	0.051-0.114	0.0065	0.165
Oil control ring side clearance	0.0014-0.0074	0.036-0.188	0.0094	0.239
Piston pin fit (loose, room temperature)	0.00005-0.00045	0.0013-0.0114	-	-
Piston fit in cylinder (loose, room temperature)	0.0015-0.0026	0.038-0.066	0.0030	0.076

Table 3-10. Pistons: all 1200 models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Compression ring gap (top and 2nd)	0.007-0.020	0.18-0.51	0.032	0.813
Oil control ring rail gap	0.009-0.052	0.23-1.32	0.065	1.651
Top compression ring side clearance	0.0020-0.0045	0.051-0.114	0.0065	0.165
2nd compression ring side clearance	0.0016-0.0041	0.041-0.104	0.0065	0.165
Oil control ring side clearance	0.0016-0.0076	0.041-0.193	0.0094	0.239
Piston pin fit (loose at room temperature)	0.00005-0.00045	0.0013-0.0114	-	-
Piston fit in cylinder (loose at room temperature)	0.0015-0.0026	0.038-0.066	0.0030	0.076

Table 3-11. Connecting rods: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Piston pin fit (loose)	0.00125-0.00175	0.0318-0.0445	0.00200	0.0508
Side play between flywheels	0.005-0.025	0.013-0.64	0.030	0.762
Fit on crankpin	0.0004-0.0017	0.010-0.043	0.0027	0.0686

Table 3-12. Flywheels: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Runout (flywheels at rim)	0.000-0.010	0.00-0.254	0.010	0.254
Runout (shaft at flywheel end)	0.000-0.002	0.00-0.0508	0.002	0.0508
End play	0.003-0.013	0.076-0.330	0.013	0.330

Table 3-13. Pinion shaft bearing: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Pinion shaft journal diameter	1.2500-1.2496	31.750-31.740	1.2494	31.735
Outer race diameter in right crankcase	1.5646-1.5652	39.741-39.756	1.5656	39.776
Bearing running clearance	0.00012-0.00088	0.0030-0.0224	-	-
Fit in cover bushing (loose)	0.0023-0.0043	0.058-0.109	0.0050	0.127

Table 3-14. Gearcase: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMIT
	in	mm	in	mm
Cam gear shaft in bushing (loose)	0.0007-0.0022	0.018-0.056	0.003	0.0762
Cam gear shaft endplay (except rear intake)	0.005-0.024	0.13-0.61	0.025	0.635
Rear intake cam gear shaft end play	0.006-0.024	0.15-0.61	0.040	1.016

Table 3-15. Sprocket shaft bearing: all models

ITEM	SPECIFICATION (INTERFERENCE FIT)
	in	mm
Outer race fit in crankcase (tight)	0.006	0.152
Inner race fit on shaft (tight)	0.006	0.152

Table 3-16. Oil pressure: at operating temperature

rpm	XL MODELS*		XR 1200X**
	psi	kPa	psi	kPa
1000	7-12	43.3-82.7	16-20	110.3-137.9
2500	10-17	68.9-117	40-44	275.8-303.4

* Pressure reading taken at oil pressure switch fitting.

** Pressure reading taken at oil cooler inlet.

Table 3-17. Electrical: XL models

COMPONENT	SPECIFICATION
Ignition timing	Not adjustable
Battery	12 V, 225 CCA, 12 Ah, sealed and maintenance free
Charging system	Single-phase, 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	0.038-0.043 in	0.97-1.09 mm
Spark plug torque	12-18 ft·lbs	16.3-24.4 Nm

Table 3-18. Electrical: XR 1200X

COMPONENT	SPECIFICATION
Ignition timing	Not adjustable
Battery	12 V, 225 CCA, 12 Ah, sealed and maintenance free
Charging system	Single-phase, 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	0.032-0.038 in	0.81-0.97 mm
Spark plug torque	12-18 ft·lbs	16.3-24.4 Nm

Table 3-19. Oil pump: all models

ITEM	NEW COMPONENTS		SERVICE WEAR LIMITS
	in	mm	in	mm
Feed/scavenger inner/outer gerotor clearance	0.003	0.08	0.004	0.102
Shaftto pump clearance	0.0025	0.064	-	-

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Article about repair motorcycles «Harley Sportster XL1200» (2012-2023): «Specifications of engine»: https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113026 <a href="https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113026">Specifications of engine</a> - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair». [url=https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113026]Specifications of engine[/url] - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair».