🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2012

Platform:

Evolution (Evo) Sportster

Engine Code:

Evolution 1200

👋 Introduction

Segment:

Cruiser motorcycle segment, known for its classic styling and V-twin engine character.

Competitors:

Other V-twin cruiser motorcycles in its displacement class from manufacturers like Indian Motorcycle, Victory Motorcycles (now defunct), and some Japanese manufacturers offering similar styles.

Model Features:

Chrome-laden styling, 1200cc Evolution V-twin engine, low seat height, comfortable riding position, iconic Sportster platform.

📋 Manual Details

Primary Coverage:

Service, Repair, Troubleshooting, Maintenance

Number Of Pages:

776

Type:

Workshop Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Engine assembly, disassembly, cylinder heads, cylinders, pistons, connecting rods, crankshaft, camshafts, valvetrain, lubrication system, oil pump, oil filter, oil cooler (if applicable), fuel injection system (EFI), throttle body, fuel pump, injectors, ignition system, spark plugs, coils, engine management system (ECM), cooling system (air-cooled).

Transmission:

5-speed constant mesh transmission, clutch, primary drive, gearbox assembly, internal components, shift mechanism, maintenance, repair.

Drivetrain:

Belt drive system, final drive belt, tensioner, rear pulley, front sprocket, maintenance, inspection, replacement.

Chassis Frame:

Frame construction, welding inspection, alignment checks, steering head bearings, swingarm, pivot bearings, rear shock absorbers, front fork assembly, maintenance, repair.

Brakes:

Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, rotor inspection and replacement, bleeding procedures, ABS (if equipped).

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, sensors, fuses, relays, ignition switch, security system (if equipped).

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, EFI system, throttle body, idle air control (IAC) motor, diagnostic connectors.

Exhaust System:

Exhaust pipes, mufflers, heat shields, mounting hardware, emissions control components.

Wheels Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, wheel alignment.

Bodywork Fittings:

Fender removal and installation, fuel tank mounting, seat assembly, fairings (if applicable), side covers, handlebars, controls.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, brake fluid flushes, spark plug replacement, drive belt inspection and adjustment, chain adjustment (if applicable), battery maintenance.

Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, starting problems, braking system malfunctions, common symptoms and their causes.

Repair:

Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems.

Diagnostics:

ECM diagnostic codes, service mode activation, sensor testing, multimeter usage for electrical diagnostics.

Performance Tuning:

Information related to fuel mapping adjustments, exhaust system modifications (where applicable in a service context), and engine component tolerances.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component replacement.

📊 Manual Specifications

Quality:

High-resolution PDF with searchable text for efficient information retrieval.

Printability:

Printable pages for convenient use in a workshop environment.

Digital Binding:

N/A (Digital PDF)

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

3.5 in x 3.813 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valve Train:

Overhead valves (OHV), 2 valves per cylinder, pushrod actuated

Horsepower:

Approx. 65-70 HP (at crankshaft, estimated)

Torque:

Approx. 70-75 ft-lbs (at crankshaft, estimated)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (Octane rating may vary by region/specification)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive:

Chain, 34/46 ratio (34-tooth front, 46-tooth rear)

Final Drive:

Belt drive, 32/65 ratio (32-tooth front pulley, 65-tooth rear sprocket)

Clutch Type:

Multi-plate, wet clutch, hydraulically actuated

📐 Dimensions

Length:

Approx. 90.5 inches (2299 mm)

Seat Height Laden:

Approx. 26.0 inches (660 mm)

Ground Clearance:

Approx. 4.5 inches (114 mm)

Dry Weight:

Approx. 569 lbs (258 kg)

Gvwr:

Approx. 932 lbs (423 kg)

Fuel Capacity:

4.5 gallons (17.0 L)

🛡️ Safety Features

Safety Standards:

Meets applicable Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.

Brakes System:

Dual-piston front caliper with 11.8-inch disc, dual-piston rear caliper with 10.2-inch disc. Optional ABS.

Lighting:

Halogen headlight, LED taillight, amber incandescent turn signals.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer (optional or integrated on some models), fuel gauge, odometer, trip meters, indicator lights.

ABS:

Optional Anti-lock Braking System (ABS) available on some configurations.

Diagnostic Port:

Diagnostic connector for interfacing with diagnostic tools (e.g., Harley-Davidson Digital Technician).

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months thereafter.

Engine Oil Type:

Harley-Davidson Genuine V-Twin Synthetic 20W-50 or equivalent meeting Harley-Davidson P/N 99818-02.

Engine Oil Capacity:

3.0 US qt (2.8 L) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant or equivalent meeting Harley-Davidson P/N 99859-02.

Primary Chain Case Oil Capacity:

2.8 US qt (2.6 L)

Transmission Oil Type:

Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant or equivalent meeting Harley-Davidson P/N 99859-02.

Transmission Oil Capacity:

Approx. 1 US qt (0.95 L)

Brake Fluid Type:

DOT 4 (for ABS models) or DOT 5.1 (for non-ABS models and recommended for systems designed for it).

Common Wear Items:

Clutch plates, drive belt, brake pads, wheel bearings, fork seals.

Potential Electrical Gremlins:

Occasional issues with charging systems (regulator/rectifier), starter solenoid, or loose connections can occur with age and mileage.

📚 Vehicle History

Founding Year:

1903

Brand Identity:

Iconic American motorcycle manufacturer with a long history of V-twin engines and custom culture.

Sportster Introduction:

The Sportster line was introduced in 1957.

Xl1200C Introduction:

The XL1200C model was introduced in 1996, representing a more upscale and customizable version of the Sportster.

Manufacturing Location:

USA (Harley-Davidson's York, Pennsylvania and Milwaukee, Wisconsin facilities historically)

🏆 Awards & Recognition

Awards History:

While specific annual awards for the 2012 model are not readily aggregated, the Harley-Davidson Sportster line is consistently recognized for its iconic status and enduring appeal in the cruiser motorcycle market.