Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners seeking to perform their own maintenance and repairs, independent mechanics
Competitors:
Other V-twin cruisers of the era (e.g., Indian Chief, various Japanese cruisers)
Vehicle Strengths:
Classic styling, torquey V-twin engine, comfortable riding position for cruising
Manual Value Proposition:
Empowers owners with the knowledge to maintain and repair their Sportster, saving on dealership costs and ensuring proper upkeep.
Scope:
Complete service, maintenance, and troubleshooting for the Harley-Davidson XL1200R Sportster 2007
Specific Coverage:
All mechanical and electrical systems
Estimated Pages:
Approximately 600-800 (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Manual / Repair Manual
Powertrain:
Engine, Transmission, Clutch, Drivetrain (Belt Drive)
Chassis:
Frame, Suspension (Front Forks, Rear Shocks), Steering, Wheels, Tires, Brakes (Front & Rear)
Electrical:
Ignition System, Lighting System, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Battery, Gauges, Indicators, Wiring Diagrams, Electronic Control Module (ECM)
Fuel System:
Carburetion (Keihin CV Carburetor), Fuel Tank, Fuel Lines, Fuel Filter
Exhaust System:
Exhaust Pipes, Mufflers, Heat Shields
Bodywork:
Fenders, Fuel Tank, Seat, Handlebars, Footpegs, Primary Cover, Derby Cover
Maintenance:
Routine service, oil changes, filter replacements, brake fluid changes, spark plug service, battery maintenance, belt inspection/adjustment
Troubleshooting:
Diagnostic procedures for common issues, electrical fault finding, engine performance problems
Repair:
Engine overhaul, transmission repair, suspension component replacement, brake caliper overhaul, electrical component repair/replacement
Diagnostics:
Step-by-step diagnostic flowcharts and testing procedures
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Detail Level:
Detailed step-by-step instructions with accompanying diagrams and illustrations
Engine Type:
Air-cooled, 45-degree V-twin, Evolution Engine
Displacement:
73.4 cubic inches (1202cc)
Bore X Stroke:
3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)
Horsepower:
Approximately 60-65 HP (Estimated, depending on exhaust and tuning)
Torque:
Approximately 67-70 lb-ft @ 3200 RPM (Estimated)
Carburetor:
Keihin 40mm CV (Constant Velocity) carburetor
Fuel Delivery:
Gravity Feed
Ignition Type:
Electronic Ignition (Magneti Marelli or similar)
Oil Type:
Harley-Davidson 20W50 Motorcycle Oil (or equivalent API SG, SE, SF, SG rated)
Oil Capacity:
3.0 US quarts (2.8 L) with filter change
Transmission Type:
5-speed constant mesh
Optional Transmission:
N/A (Standard 5-speed for XL1200R)
Clutch Type:
Wet, multi-plate, diaphragm spring
Drive Type:
Carbon reinforced, 1.600 ratio final belt drive
Transmission Oil Type:
Harley-Davidson Formula+ (or equivalent SAE 80W90 Hypoid Gear Oil)
Transmission Oil Capacity:
2.7 US quarts (2.5 L)
Length:
88.0 in. (2235 mm)
Width:
35.0 in. (889 mm) (Overall)
Height:
47.5 in. (1207 mm) (Handlebar height)
Wheelbase:
60.0 in. (1524 mm)
Ground Clearance:
4.6 in. (117 mm)
Dry Weight:
575 lbs (261 kg)
Gross Vehicle Weight Rating:
975 lbs (442 kg)
Fuel Capacity:
4.8 US gallons (18.2 L)
Front Wheel:
16-inch (Spoke or Chrome Steel options)
Rear Wheel:
16-inch (Spoke or Chrome Steel options)
Bolt Pattern:
N/A (Harley-Davidson hub assembly)
Crash Test Ratings:
N/A (Motorcycles are not typically crash-tested by governmental agencies in the same manner as cars)
Braking System:
Dual-piston caliper front brake, Single-piston caliper rear brake
Lighting:
Halogen headlight, LED tail light, Incandescent front and rear turn signals
Frame Construction:
Steel cradle frame
Handlebar Design:
Riser-mounted drag-style handlebars for control
Infotainment System:
Basic analog gauges (speedometer, tachometer), odometer, trip meter, neutral indicator, oil pressure light, turn signal indicators, high beam indicator.
ABS:
Not equipped with ABS as standard for the 2007 XL1200R.
Connectivity Features:
N/A (No Bluetooth or smartphone integration on this model).
Oil Change Interval:
Every 5,000 miles (8,000 km) or annually
Transmission Oil Change:
Every 10,000 miles (16,000 km) or annually
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Primary Chain Tension:
Check every 5,000 miles (8,000 km)
Belt Tension Inspection:
Check every 5,000 miles (8,000 km)
Fork Oil Type:
Harley-Davidson Genuine Fork Oil (or equivalent SAE 10W)
Fork Oil Capacity:
10.7 US fl oz (317 ml) per fork leg
Common Wear Items:
Clutch plates, brake pads, wheel bearings, belt drive components
Potential Electrical Issues:
Regulator/rectifier failure, stator issues, battery drain
Carburetor Tuning:
CV carburetor may require fine-tuning for optimal performance, especially with aftermarket exhaust or intake.
Transmission Noise:
Some Sportsters can exhibit transmission noise; the manual would detail acceptable operating noise levels and potential causes for excessive noise.
Brand Origin:
Founded in Milwaukee, Wisconsin, USA in 1903.
Brand Philosophy:
Iconic American motorcycle manufacturer known for its V-twin engines and custom culture.
Sportster Lineage:
The Sportster line has been in continuous production since 1957, making it one of the longest continuously produced motorcycle platforms in the world.
Xl1200R Positioning:
The 'R' designation signifies the 'Roadster' model, typically featuring a more performance-oriented stance with dual front disc brakes (on some earlier models, but single on 2007) and upgraded suspension components compared to standard Sportsters.
Manufacturing Location:
Milwaukee, Wisconsin, USA
Production Years Xl1200R:
Introduced in 2004, continued through 2008 (with modifications).
