Harley Davidson XL1200NS Sportster Iron 2020 Service Manual

The Iron 1200 is basically a bored-out Iron 883, a stripped-down, blacked-out Sportster that harks back to the roaring ’70s. It has small mini-ape handlebars, a solo seat, a 3.3-gallon teardrop tank with striped AMF-style tank graphics and a mostly black engine, with chrome limited to the pushrod tubes and blocks. It was introduced in 2018 and Harley left the 2020 bike unchanged. The wheels are black 9-spoke cast aluminum, 19 inches at the front and 16 inches at the rear, wearing Michelin Scorcher 31 tires, and the exhaust headers and mufflers are black. The 2020 US price was $9,999, which makes it a custom look for under $10,000, and it was available with ABS.

Power comes from the air-cooled, rubber-mounted 1,202cc Evolution V-twin, with an 88.9mm bore, a 96.8mm stroke and a 10:1 compression ratio, fed by Electronic Sequential Port Fuel Injection. Torque is 73 lb-ft (about 99 Nm) at 3,500 rpm by the US J1349 method, or 96 Nm by the European EC 134/2014 method, and power is about 66 hp (49 kW) at 6,000 rpm. The gearbox is a 5-speed with a multi-plate wet clutch, a 38/57 chain primary drive and a 29/68 belt final drive. Harley lists fuel economy of about 48 mpg (4.9 L/100 km).

The steel-framed chassis has a 39mm fork with about 3.6 inches of travel and twin rear shocks with about 1.6 inches of travel. Rake is 30 degrees with 4.6 inches (117mm) of trail, and the wheelbase is 59.6 inches (1,515mm). Tires are a 100/90B19 57H front and a 150/80B16 77H rear, with dual-piston calipers on the front and rear discs. Lean angles are about 27 degrees to the right and 28 degrees to the left.

The bike is 86.6 inches (2,200mm) long, 36 inches (915mm) wide and 48.8 inches (1,240mm) high. Seat height is 25.7 inches (653mm) laden and 28.9 inches (735mm) unladen, with 4.3 inches (110mm) of ground clearance. The tank holds 3.3 gallons (12.5 litres), with a low-fuel warning light at about 0.8 gallons. Engine oil capacity is 2.8 quarts (2.6 litres) with the filter, and the transmission takes 1 quart. Weight is 547 lbs (248 kg) as shipped and about 564 lbs (256 kg) in running order, with a gross vehicle weight rating of 1,000 lbs.

This factory service manual covers the procedures, torque specs, and diagrams needed to keep a Sportster Iron 1200 XL1200NS running the way it was built to.