Vehicle Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson enthusiasts, owners seeking to perform their own maintenance and repairs, independent repair shops.
Key Competitors 2007:
Indian Chief, Triumph Bonneville, Kawasaki Vulcan, Honda Shadow, Yamaha V-Star.
Vehicle Identity:
The 2007 Harley-Davidson XL1200C Sportster Custom is a quintessential American cruiser known for its iconic styling, V-twin rumble, and accessible riding experience. It represents a blend of classic Harley-Davidson heritage with modern engineering.
Benefits To Owner:
Empowers owners to maintain their Sportster with confidence, diagnose issues efficiently, and perform repairs correctly, saving time and money compared to dealership service.
Engine Systems:
Engine removal and installation, disassembly and assembly of the Evolution 1200cc V-Twin engine, cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, valve train, oil pump, primary drive, clutch, and lubrication system.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (Keihin CV40), intake manifold, and throttle control systems.
Electrical System:
Ignition system (electronic ignition module, spark plugs, ignition coil), starting system (starter motor, starter solenoid), charging system (stator, regulator/rectifier), lighting system (headlight, tail light, turn signals), instrumentation (speedometer, tachometer), wiring diagrams, fuses, and battery maintenance.
Drivetrain:
Transmission (5-speed constant mesh), gearshift mechanism, drive sprocket, drive chain, and final drive maintenance.
Suspension:
Front fork (telescopic) disassembly, assembly, oil change, and seal replacement. Rear shock absorber removal, installation, and adjustment.
Brakes:
Front and rear hydraulic brake systems, brake calipers, brake master cylinders, brake lines, brake pads, brake rotors, and brake fluid replacement.
Chassis And Bodywork:
Frame inspection, front fender, rear fender, fuel tank removal and installation, seat, handlebars, controls, footpegs, and exhaust system.
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing, and spoke adjustment (if applicable).
Maintenance:
Routine maintenance checks, oil changes, filter replacements, spark plug replacement, brake fluid flush, chain lubrication and adjustment, battery maintenance, and tire pressure checks.
Repair:
Complete engine rebuild procedures, transmission gear replacement, clutch component replacement, electrical component troubleshooting and replacement, brake system repairs, suspension servicing, and exhaust system repair/replacement.
Troubleshooting:
Diagnostic charts and symptom-based troubleshooting for common issues related to engine performance, electrical systems, starting and charging problems, and braking issues.
Depth Level:
Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission overhauls, including detailed torque specifications, tolerances, and special tool requirements.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200 cc (73.3 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Horsepower Estimate:
Approximately 67 HP @ 5000 RPM (manufacturer data varies by test)
Torque Estimate:
Approximately 70 lb-ft @ 3500 RPM (manufacturer data varies by test)
Fuel Delivery:
Carbureted: Keihin CV40 (Constant Velocity Carburetor)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Capacity:
3.0 US quarts (2.8 liters) with filter change
Oil Type Spec:
Harley-Davidson Genuine V-Twin 20W-50 or equivalent API SG, JASO-FD certified motorcycle oil.
Ignition Type:
Electronic, spark ignition
Cooling Method:
Air-cooled
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 1.5" width
Final Drive:
Belt drive (70-tooth pulley, 29-tooth engine sprocket, 138-tooth final belt)
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Fluid Type:
Harley-Davidson Genuine Formula SAE 50 or equivalent
Transmission Fluid Capacity:
24 US fluid ounces (0.71 liters)
Length:
Approx. 90.5 inches (2299 mm)
Width:
Approx. 36.5 inches (927 mm)
Height:
Approx. 45.1 inches (1145 mm)
Wheelbase:
Approx. 60.0 inches (1524 mm)
Ground Clearance:
Approx. 4.7 inches (119 mm)
Dry Weight:
Approx. 540 lbs (245 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 939 lbs (426 kg)
Fuel Capacity:
4.0 US gallons (15.1 liters)
First Service Mileage:
1000 miles (1600 km) or 6 months
Subsequent Service Mileage:
Every 5000 miles (8000 km) or 12 months thereafter (whichever comes first)
Engine Oil Change Interval:
Every 5000 miles (8000 km) or 12 months
Primary Chain Case Oil Change Interval:
Every 10,000 miles (16,000 km) or 24 months
Engine Oil Viscosity:
20W-50
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Common Wear Items:
Clutch wear, fork seal leaks, belt drive wear (tension and alignment are critical), exhaust gasket leaks, and potential carburetor jetting adjustments for altitude/climate.
Electrical Considerations:
Battery charging system (stator/regulator issues can occur), aging wiring harness connections.
Harley Davidson Founding:
Founded in 1903 in Milwaukee, Wisconsin, by William S. Harley and Arthur Davidson.
Sportster Lineage:
The Sportster line, first introduced in 1957, is one of Harley-Davidson's longest-running and most iconic model families, evolving from the 'Ironhead' to the 'Evolution' engine.
Evolution Engine Introduction:
The Evolution engine (known colloquially as 'Blockhead') was introduced in 1984, replacing the Shovelhead engine, offering improved reliability and performance.
Manufacturing Location:
Milwaukee, Wisconsin, USA
