Harley Davidson XR1200 2010 Workshop Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 64389

Etiquetas: 2010 Harley Davidson Motorcycle Motorcycles Sportster XR1200

Variantes de producto

Descripción

The XR1200, produced from 2008 to 2012, represents a significant evolution in the lineup, blending its iconic V-twin character with a more performance-oriented sport custom and muscle bike design. Inspired by racing heritage, particularly the XR750, the XR1200 offers a dynamic riding experience with its air-cooled, 1200cc V-twin engine featuring fuel injection and a 5-speed manual transmission. This model was developed with a focus on enhanced handling and power, making it a compelling choice for riders seeking a more spirited machine that still embodies the distinctive spirit. This workshop service repair manual provides comprehensive English-language coverage for all XR1200 styles, offering detailed step-by-step instructions for complete disassembly, service, repair, and troubleshooting. It covers all major systems, including the chassis, fuel, cooling, engine, clutch, transmission, brakes, suspension, steering, frame, and electrical systems, complete with detailed wiring diagrams. Designed for both do-it-yourself enthusiasts and professional mechanics, this manual serves as an invaluable resource for maintaining, diagnosing, and repairing the XR1200, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XR1200

Year:

Generation

Generation Code:

XR1200/XR1200X (though this manual is specific to the XR1200)

Codes

Vin Code:

Not specified in product info, typically found on vehicle chassis.

👋 Introduction

Market Position

Target Audience:

Do-it-yourself enthusiasts and professional mechanics

Segment:

Sport Custom / Muscle Bike

Competitive Analysis

Value Proposition:

Cost-effective alternative to dealership service, providing complete factory repair information.

Key Features

Manual Features:

• Hundreds of pages

• Printable in entirety or selected pages

• Hundreds of photos and illustrations

• Detailed substeps

• Notes, cautions, and warnings

• Numbered instructions

• Bold figure numbers

• Enlarged inset illustrations

• Numbered table of contents

• Troubleshooting and electrical service combined with wiring diagrams

• Works on all PC-based Windows operating systems and Mac

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive coverage for all XR1200 styles

Page Count

Estimated Page Count:

Hundreds of pages (precise count not provided)

Manual Type

Manual Classification:

Workshop Service Repair Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

Diagnostic Level:

In-depth, professional quality, suitable for do-it-yourselfers and experienced mechanics

📊 Manual Specifications

File Format

File Type:

Software Requirements:

Adobe PDF Reader

Print Quality

Print Permission:

Printable without any restriction

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-Twin, Air-Cooled

Bore X Stroke:

Refer to manual for specific bore and stroke dimensions.

Performance

Engine Displacement:

1200cc (Approximate, specific engine code not provided in product info)

Horsepower:

Approx. 96 hp (actual figures may vary and are detailed in the manual).

Torque:

Approx. 74 ft-lbs (actual figures may vary and are detailed in the manual).

Fuel System

Fuel Delivery:

Fuel Injection (EFI)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Optional

Optional Transmission:

Features

Transmission Features:

Wet, multi-plate clutch

Final Drive Type:

Belt Drive

📐 Dimensions

Exterior

Wheelbase:

Refer to manual for specific dimensions.

Seat Height:

Refer to manual for specific dimensions.

Weights

Dry Weight:

Refer to manual for specific weights.

🛡️ Safety Features

Ratings

Safety Standards:

Manual covers safety-related procedures and components.

Active Features

Braking System:

Disc brakes front and rear (specific caliper and rotor details in manual)

Passive Features

Frame Construction:

Steel frame (specific construction details in manual)

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer and speedometer with a digital display for odometer, trip meters, and gear indicator. Specific details on diagnostics accessible through the dashboard may be included.

Driver Assistance

ABS was an optional feature on the XR1200. The manual will cover its operation and maintenance if equipped.

Connectivity

Diagnostic Ports:

The manual will detail the location and use of diagnostic connectors for electronic diagnostics and tuning.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

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.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Heritage Focus:

Harley-Davidson's focus on performance and racing heritage, drawing inspiration from the XR750.

Model Evolution

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

Production Period:

XR1200 was produced from 2008 to 2012.

🏆 Awards & Recognition

Recognitions

Media Reviews:

The XR1200 received positive reviews for its handling and performance, often being praised as a more sporting Harley-Davidson. Specific awards or 'bike of the year' accolades are not detailed in the product description.