Segment:
Cruiser Motorcycle
Target Audience:
Owners of the 2002 Harley-Davidson XL1200C Sportster Custom seeking to perform maintenance and repairs.
Original Manual Provider:
Harley-Davidson Motor Company
Primary Benefit:
Empowers owners to perform maintenance and repairs, saving time and money compared to dealership service.
Digital Convenience:
PDF format allows for easy searching, printing of specific pages, and digital storage.
Engine Mechanical:
Engine disassembly, inspection, assembly, tuning, lubrication systems, cooling systems (air-cooled).
Fuel System:
Carburetor (Keihin CV), fuel lines, fuel pump, fuel tank.
Ignition System:
Ignition module, spark plugs, ignition coils, timing.
Transmission Drivetrain:
5-speed transmission, clutch, primary drive, final belt drive, gearbox disassembly and reassembly.
Chassis Frame:
Frame inspection, steering head, swingarm, bearings.
Suspension:
Front fork (telescopic, cartridge damping), rear shock absorbers, adjustments, rebuilds.
Brakes:
Front and rear hydraulic disc brakes, caliper service, master cylinder, brake fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system, lighting, instrumentation, switches.
Wheels Tires:
Wheel bearing service, tire selection and maintenance, spoke wheel truing (if applicable).
Bodywork Trim:
Fenders, fuel tank, seat, handlebars, controls, exhaust system removal and installation.
Routine Maintenance:
Oil changes, filter replacement, chain/belt adjustment, spark plug replacement, air filter service, brake system checks.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, electrical system troubleshooting.
Repair Rebuilds:
Engine overhaul, transmission rebuild, carburetor rebuilding, fork seal replacement, brake caliper service.
Adjustments Tuning:
Carburetor idle and mixture adjustment, ignition timing verification, clutch adjustment, belt tension adjustment.
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Suitable for DIY enthusiasts and professional technicians.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200 cc (73.2 cu in)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Horsepower Est:
Approx. 60-65 HP (at crank)
Torque Est:
Approx. 67-70 ft-lbs (at crank)
Carburetor Model:
Keihin CV (Constant Velocity)
Fuel Delivery:
Carbureted
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
Harley-Davidson SYN3 Synthetic or equivalent motorcycle-specific V-twin oil (SAE 20W-50 recommended for warm weather).
Oil Capacity W Filter:
3.0 US qt (2.8 L)
Safety Certification:
Not applicable for motorcycles in the same way as automobiles; adheres to relevant motorcycle safety standards.
Braking System:
Dual hydraulic disc brakes (front and rear) with single-piston calipers.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame Construction:
Steel frame for rigidity and rider protection.
Rider Controls:
Ergonomically placed handlebars and foot controls for rider command.
Infotainment System:
N/A (No integrated infotainment system; relies on aftermarket audio or communication devices).
Driver Assistance Features:
N/A (No electronic driver assistance features common in modern vehicles).
Connectivity Features:
N/A (No built-in Bluetooth, USB, or smartphone integration).
Instrument Cluster:
Analog speedometer, tachometer (optional on some models), odometer, trip meter, engine oil pressure warning light, turn signal indicators, high beam indicator.
First Service:
Typically at 1,000 miles (1,600 km) for initial break-in service (check/adjustments, oil change).
Regular Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Primary Chain Tensioner:
Inspect and adjust as needed every 2,500 miles (4,000 km) or if noise is present.
Spark Plugs:
Replace every 10,000-15,000 miles (16,000-24,000 km).
Belt Drive Tension:
Check and adjust as needed every 5,000 miles (8,000 km).
Engine Oil:
Harley-Davidson SYN3 Synthetic 20W-50 or equivalent motorcycle-specific V-twin oil.
Transmission Oil:
Harley-Davidson Transmission Lubricant or equivalent.
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Lubricant or equivalent (same as transmission oil).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specify type and weight based on service manual (e.g., Showa SS-47 or equivalent 5W-10W fork oil).
Carburetor Tuning:
Keihin CV carburetors may require periodic adjustments for idle and fuel mixture, especially with altitude or exhaust changes.
Primary Chain Tensioner:
Automatic tensioner can wear out, leading to rattling noises; manual replacement or upgrade is often recommended.
Rear Shock Seals:
Older shock absorber seals can degrade over time, leading to leaks.
Wiring Harness Connections:
Corrosion or loose connections can cause intermittent electrical issues, particularly in older bikes exposed to elements.
Brand Origin:
Founded in 1903 in Milwaukee, Wisconsin, USA.
Sportster Legacy:
The Sportster line is one of Harley-Davidson's longest-running model families, dating back to 1957.
Xl1200C Introduction:
The 'Custom' variant of the Sportster 1200 began evolving into its more recognized form in the late 1980s and early 1990s, with specific styling cues becoming prominent by 2002.
Key Features 2002:
Typically featured a lower seat height, wider handlebars, chrome accents, and often a slightly larger fuel tank compared to base Sportster models.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri)
Model Year Context:
Represents the early 2000s era of Harley-Davidson's Evolution engine development.
