Covered Systems:
• General Information
• Maintenance
• Chassis
• Fuel System
• Cooling System
• Engine
• Clutch
• Engine Lubrication System
• Engine Removal/Installation
• Drive
• Transmission
• Wheels/Tires
• Final Drive
• Brakes
• Suspension
• Steering
• Frame
• Electrical System
• Wiring Diagram
Fuel System Detail:
Includes fuel pump, injectors, throttle body, fuel pressure regulator, and EVAP system diagnostics and repair.
Cooling System Detail:
Details on oil cooling system components, hoses, and fluid checks.
Engine Detail:
Covers cylinder heads, valves, camshafts, pistons, connecting rods, crankshaft, and engine assembly/disassembly.
Clutch Detail:
Procedure for clutch assembly, adjustment, and replacement of friction plates and springs.
Engine Lubrication System Detail:
Information on the oil pump, oil filter, oil lines, and oil passages.
Drive Detail:
Covers the primary drive system, including the clutch, starter, and drive gears.
Transmission Detail:
Internal transmission components, gear shift mechanism, and maintenance procedures.
Wheels Tires Detail:
Wheel bearing inspection and replacement, tire mounting and balancing, and recommended tire pressures.
Final Drive Detail:
Inspection and maintenance of the belt drive system, including belt tension and alignment.
Brakes Detail:
Hydraulic system for front and rear brakes, caliper service, rotor inspection, and bleeding procedures. ABS system troubleshooting if equipped.
Suspension Detail:
Front fork service (oil changes, seal replacement), rear shock absorber adjustment and replacement.
Steering Detail:
Headset bearing inspection, adjustment, and replacement. Handlebar and control adjustments.
Frame Detail:
Frame inspection for damage, alignment checks, and associated component mounting.
Electrical System Detail:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter system, and electronic control module (ECM) troubleshooting.
Wiring Diagram Detail:
Complete, detailed wiring diagrams for all electrical circuits, color-coded for ease of tracing.
Repair Procedures:
• Step-by-step instructions for complete disassembly
• Service procedures
• Repair procedures
• Troubleshooting
• Electrical service procedures
• Diagnosis and repair of electrical system problems
Diagnostic Procedures:
Troubleshooting flowcharts for common issues, diagnostic fault codes (if applicable and covered by the manual).
Installation Procedures:
Guidance for installing accessories or replacing major components.
Diagnostic Level:
In-depth, professional quality, suitable for do-it-yourselfers and experienced mechanics
Recommended Service Intervals:
Detailed service intervals for engine oil, transmission oil, primary chain case oil, filter changes, spark plugs, and other maintenance items are provided within the manual.
Engine Oil Specification:
Specific Harley-Davidson recommended oil viscosity and API service classification will be detailed in the manual (e.g., SAE 20W50).
Transmission Fluid Specification:
Specific transmission lubricant type and capacity will be listed.
Primary Chain Case Fluid Specification:
Specific fluid type and capacity for the primary drive system will be detailed.
Common Wear Items:
The manual will guide on the inspection and replacement of wear items such as brake pads, clutch plates, tires, and suspension components.
Heritage Focus:
Harley-Davidson's focus on performance and racing heritage, drawing inspiration from the XR750.
Model Development:
The XR1200 was developed as a more performance-oriented motorcycle, initially for European markets, and later introduced to North America. It represents a departure from traditional Harley-Davidson styling while retaining the V-twin character.
Production Period:
XR1200 was produced from 2008 to 2012.