Segment:
Cruiser Motorcycle - Custom variant of the Sportster line
Target Audience:
Harley-Davidson Sportster XL 1200CA owners and independent repair shops
Competitors:
Indian Scout, Triumph Bonneville, other V-twin cruisers in the mid-weight class
Model Focus:
The 'CA' designation typically signifies custom features and often includes accessories like spoke wheels, custom paint, and enhanced ergonomics compared to base models.
Manual Advantage:
Provides authoritative, manufacturer-level repair information for DIY enthusiasts and professional mechanics alike.
Engine Mechanical:
Cylinder heads, cylinders, pistons, crankshaft, connecting rods, valve train, lubrication system
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel lines, evaporative emissions control (EVAP)
Ignition System:
Ignition module, spark plugs, ignition coils, crankshaft position sensor, camshaft position sensor
Transmission:
Clutch, primary drive, gearbox (5-speed), shift mechanism, final drive
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), horn, instrument cluster, ECU/ECM
Chassis Suspension:
Front forks (39mm), rear shocks, steering head, swingarm, wheel bearings
Brakes:
Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, ABS (if equipped)
Wheels Tires:
Wheel types, tire specifications, tire pressure, wheel balancing
Bodywork Fittings:
Fenders, fuel tank, seat, handlebars, controls, mirrors, exhaust system
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), common symptoms and remedies, wiring diagrams
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake fluid flush, spark plug replacement
Engine Repair:
Top-end rebuild, bottom-end overhaul, component replacement (e.g., gaskets, seals)
Transmission Repair:
Clutch adjustment and replacement, gearbox disassembly and reassembly
Electrical Diagnostics:
Troubleshooting charging system failures, ignition problems, lighting circuits
Suspension Service:
Fork seal replacement, shock absorber replacement, steering bearing service
Brake Service:
Brake pad replacement, caliper service, bleeding brake system
Wiring Diagrams:
Detailed schematics for all electrical systems
Torque Specifications:
All critical fasteners torqued to factory specifications
Depth:
Comprehensive; covers basic maintenance to complete engine and transmission rebuilds
Diagnostic Tools:
Information for use with diagnostic scan tools (e.g., Harley-Davidson Digital Technician)
Engine Type:
Evolution (Evo) V-Twin, Air-Cooled
Displacement:
1202 cc (73.4 cubic inches)
Bore X Stroke:
3.000 in x 3.8125 in (76.2 mm x 96.8 mm)
Valve Train:
Overhead Valve (OHV), 2 valves per cylinder
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Horsepower:
Approximately 67 hp @ 5750 rpm (manufacturer estimate, actual may vary)
Torque:
Approximately 71 lb-ft @ 3500 rpm (manufacturer estimate, actual may vary)
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 minimum recommended
Fuel Tank Capacity:
3.3 US gallons (12.5 L)
First Service:
1000 miles or 12 months, whichever comes first
Subsequent Service:
Every 5000 miles or 12 months, whichever comes first
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API CI-4 rated)
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Case Lubricant (or SAE 15W-40 API CG-4 or higher)
Transmission Oil:
Harley-Davidson Genuine Formula + (or SAE 85W-140 GL-5)
Brake Fluid:
DOT 4 hydraulic brake fluid
Coolant:
N/A (Air-Cooled Engine)
Engine Oil Capacity:
3.0 US quarts (2.8 L) with filter change
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, belt drive wear
Electrical Concerns:
Occasional issues with regulator/rectifier or battery charging system over time, potential for wiring harness chafing if not properly routed.
Engine Performance Tuning:
The manual will cover recalibration of the EFI for optimal performance and emissions compliance, especially after modifications.
Legacy:
Harley-Davidson has a long-standing heritage of building V-twin motorcycles, with the Sportster line dating back to 1957.
Sportster Line:
The Sportster has evolved significantly over the decades, maintaining its core identity while incorporating modern technology and styling updates.
Xl 1200Ca Specifics:
The XL 1200CA is part of the 'Custom' variants, offering a blend of classic styling with modern rider aids and ergonomic enhancements.
Manufacturing:
Assembled in York, Pennsylvania, U.S.A.
