Harley Davidson Sportster XL1200C Custom 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XL1200C Custom Year: 2005 Product Type: Service Repair Manual Product Format: PDF Codes Engine Code: Evolution V-Twin (Air-Cooled) 👋 Introduction Market Position...

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Taper: Motorcycle

Distributeur:

UGS: 444089

Mots clés: 2005 Harley Davidson Misc Motorcycle Motorcycles Sportster XL1200C Custom

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster XL1200C Custom

Year:

Product Type:

Service Repair Manual

Product Format:

Codes

Engine Code:

Evolution V-Twin (Air-Cooled)

👋 Introduction

Market Position

Market Segment:

Cruiser motorcycle

Target Audience:

Harley-Davidson Sportster owners and independent motorcycle repair technicians.

Competitive Analysis

Competitors:

Other V-twin cruisers from brands like Indian, Victory, and custom builders.

Key Features

Vehicle Highlight:

The XL1200C Custom is known for its classic styling, comfortable riding position, and the iconic Harley-Davidson V-twin rumble, making it a popular choice for riders seeking a blend of heritage and performance.

Manual Value Proposition:

This manual provides the essential technical knowledge to maintain, troubleshoot, and repair the 2005 Sportster XL1200C Custom, empowering owners and technicians with comprehensive factory-level information.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and overhaul of the 2005 Harley-Davidson Sportster XL1200C Custom

Technical Assumption:

Assumes technician is fully conversant with general motorcycle repair practices and tools.

Page Count

Estimated Pages:

Approximately 600-800 pages (typical for comprehensive service manuals)

Manual Type

Type:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Digital PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine assembly, disassembly, inspection, and repair; transmission overhaul and maintenance; clutch system diagnostics and service.

Chassis Suspension:

Front fork service and overhaul (including seals and oil); rear shock absorber replacement and adjustment; swingarm and bearing service; wheel and tire maintenance.

Brakes:

Front and rear brake system inspection, service, and repair; caliper overhaul; brake fluid replacement; hydraulic system troubleshooting.

Electrical System:

Ignition system diagnostics; lighting system troubleshooting; starter motor and charging system service; battery maintenance and testing; wiring diagrams and component identification.

Fuel System:

Carburetor (Keihin CV 40) disassembly, cleaning, adjustment, and overhaul; fuel tank inspection and maintenance; fuel lines and fittings service.

Exhaust System:

Exhaust pipe and muffler inspection, removal, and installation; gasket replacement.

Body Frame:

Fender and tank removal/installation; seat service; handlebar and control component service.

Procedures Included

Maintenance:

Scheduled maintenance procedures, including oil and filter changes, spark plug replacement, air filter service, drive belt inspection, and brake adjustments.

Diagnostics:

Troubleshooting guides for common issues related to engine performance, electrical systems, and drivetrain.

Repair:

Detailed step-by-step repair instructions for all major mechanical and electrical components.

Overhaul:

Complete rebuild procedures for engine, transmission, and fork assemblies.

Adjustments:

Precise instructions for clutch adjustment, carburetor tuning, and ignition timing (if applicable).

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes to full engine rebuilds and complex electrical diagnostics.

Diagnostic Tools:

References for specialized tools and diagnostic procedures required for accurate fault finding.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (standard for high-quality PDF manuals)

Print Quality

Image Resolution:

High resolution, suitable for printing with clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)

Compression Ratio:

8.8:1

Valve Train:

Overhead valve (OHV), two valves per cylinder

Ignition System:

Electronic CDI with spark advance

Performance

Horsepower Est:

Approx. 60-65 HP (at crankshaft)

Torque Est:

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

Fuel System

Carburetor Model:

Keihin CV 40mm

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 or higher recommended

Lubrication

Oil Type Engine:

Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 or equivalent

Oil Capacity Engine W Filter:

3.5 US quarts (3.3 Liters)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Belt drive

Fluid Specifications

Transmission Oil Type:

Harley-Davidson Formula Plus Primary Chaincase Lubricant SAE 50 or equivalent

Fluid Capacities

Transmission Oil Capacity:

25-28 US fluid ounces (0.74-0.83 Liters)

📐 Dimensions

Exterior

Length:

Approximately 90.1 inches (2289 mm)

Width Handlebar:

Approximately 34.5 inches (876 mm)

Height:

Approximately 49.0 inches (1245 mm)

Interior

Seat Height Laden:

Approximately 25.5 inches (648 mm)

Ground Clearance:

Approximately 4.4 inches (112 mm)

Weights

Dry Weight:

Approximately 567 lbs (257 kg)

Gross Vehicle Weight Rating:

Not specified, but typically around 900-1000 lbs

Fuel Capacity:

4.5 US gallons (17 Liters)

🛡️ Safety Features

Ratings

Safety Standards:

Complies with applicable US EPA, CARB, and DOT regulations for motorcycles.

Active Features

Braking System:

Hydraulically actuated front and rear disc brakes.

Lighting:

Halogen headlamp, LED tail lamp, amber lens front turn signals, clear lens rear turn signals.

Passive Features

Frame Construction:

Steel frame with integrated oil tank.

Tire Specifications:

Front: 100/90-16 54H; Rear: 150/80B16 77H

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer with integrated tachometer and odometer, fuel gauge, oil pressure light, engine diagnostic indicator.

Audio System:

Not standard on this model.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature and may or may not be present on all 2005 XL1200C models. The manual will cover its diagnostics if equipped.

Connectivity

Connectivity Features:

No integrated smartphone or wireless connectivity features.

🔧 Maintenance

Service Intervals

First Service:

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

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first.

Drive Belt Inspection:

Inspect and adjust tension at every service interval.

Fork Oil Change:

Recommended every 15,000-20,000 miles or if performance degrades.

Fluid Specifications

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Fluid Capacities

Brake Fluid Capacity:

Refer to manual for specific caliper and master cylinder capacities.

Known Issues

Common Wear Items:

Clutch plates, brake pads, drive belt, wheel bearings, and fork seals are common wear items.

Carburetor Tuning:

CV carburetor may require periodic adjustment for optimal performance, especially with altitude or exhaust modifications.

Electrical Connections:

Corrosion in electrical connectors can sometimes lead to intermittent issues, requiring inspection and cleaning.

Part Numbers

Oil Filter Part Number:

Typically Harley-Davidson 63796-77A or equivalent aftermarket.

Spark Plug Part Number:

Typically Harley-Davidson 32312-99A (Twin Cam) or equivalent for Evolution, often NGK DCPR7E or H-D equivalent.

📚 Vehicle History

Brand Heritage

Brand Origin:

Harley-Davidson Motor Company, founded in Milwaukee, Wisconsin, USA.

Sportster Legacy:

The Sportster line, introduced in 1957, is one of the longest continuously produced motorcycle lines in the world, evolving from performance-oriented bikes to iconic cruisers.

Model Evolution

Xl1200C Custom Evolution:

The XL1200C Custom variant focuses on customizable styling and rider comfort, often featuring chrome accents, larger front wheels, and a two-up seat.

Production

Production Location:

Manufactured in the United States.

Model Year Significance:

The 2005 model year represents a mature iteration of the XL1200C Custom, refined from previous generations with established engineering and styling cues.

🏆 Awards & Recognition

Recognitions

Model Accolades:

While specific awards for the 2005 model year are not widely publicized, the Sportster line consistently receives acclaim for its iconic status and customization potential.

Ratings

Rider Satisfaction:

High rider satisfaction ratings for its classic riding experience and build quality.

Certifications

Manual Quality:

This manual aims to meet industry standards for technical documentation, providing accurate and actionable information for professional repair.