Harley Davidson XL1200R 2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200R Year: 2010 Model Designation: Sportster 1200 Roadster 👋 Introduction Market Position Segment: Cruiser Motorcycle Competitive Analysis Key Competitors: Directly competes with other...

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Taper: Motorcycle

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UGS: 439371

Mots clés: 2010 Harley Davidson Motorcycle Motorcycles Sportster XL1200R

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XL1200R

Year:

Model Designation:

Sportster 1200 Roadster

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Competitive Analysis

Key Competitors:

Directly competes with other American V-twin cruisers in its class, offering a balance of performance and classic styling. Competitors often include models from Indian Motorcycle and custom bike builders.

Key Features

Model Appeal:

The XL1200R Roadster is known for its sporty riding position, higher ground clearance compared to other Sportsters, and a focus on rider engagement and performance, distinguishing it from more laid-back cruiser models.

Manual Value Proposition

Utility:

Provides comprehensive, actionable information for maintenance, diagnostics, and repair, empowering owners and technicians to effectively service the Harley-Davidson XL1200R 2010, ensuring optimal performance and longevity.

Manual Characteristics

Clarity Of Explanation:

Designed for simplicity, with step-by-step instructions intended to allow even less experienced personnel to perform satisfactory service.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service Repair

Page Count

Total Pages:

Manual Type

Type:

Service Manual / Workshop Manual

Language

Language:

English

Format

File Format:

Delivery Method

Instant Download:

Available via instant download upon completion of secure payment, eliminating shipping costs and delays.

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and repair, including top-end (cylinder head, valves, piston) and bottom-end (crankshaft, connecting rods, oil pump) components.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, fuel lines, pressure regulator, and related sensors.

Ignition System:

Ignition module, spark plugs, ignition coils, and related wiring.

Transmission:

Clutch operation, primary drive, transmission gear inspection and replacement, shift mechanism, and transmission fluid maintenance.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, switches, and instrument cluster.

Chassis:

Frame inspection and repair, front fork assembly (disassembly, seal replacement, fluid changes), rear shock absorbers, swingarm, and bearings.

Brakes:

Front and rear brake systems, brake caliper overhaul, master cylinder repair, brake pad replacement, brake fluid flush and replacement, and ABS system (if applicable).

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure checks, tire wear assessment, and wheel balancing.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, and mounting hardware.

Bodywork And Trim:

Fenders, fuel tank mounting and removal, seat, handlebars, and minor cosmetic component adjustments.

Procedures Included

Maintenance:

Detailed procedures for routine maintenance tasks, including oil changes, filter replacements, spark plug checks, chain adjustment (if applicable), and lubrication points.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common mechanical and electrical issues, including symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major vehicle components, including detailed disassembly, cleaning, inspection, part replacement, and reassembly.

Installation:

Procedures for installing new or replacement parts and accessories, ensuring correct alignment and functionality.

Adjustments:

Precise instructions for adjustments to critical systems, such as throttle cable, clutch lever, and suspension settings.

Torque Values:

Comprehensive torque specifications for all critical fasteners and threaded connections are provided, ensuring proper assembly and preventing component failure.

Technical Depth

Depth:

Comprehensive, bumper-to-bumper coverage suitable for professional mechanics and experienced DIY enthusiasts. Includes detailed explanations, pictorial diagrams, and exploded views.

Special Tools:

Includes explicit references and illustrations for required special service tools (SSTs), crucial for accurate and safe repairs. The manual specifies tool numbers where applicable.

Wear Limits:

Provides precise wear limits and tolerances for various engine and chassis components, enabling accurate assessment of component condition during servicing.

📊 Manual Specifications

File Format

Printability:

Yes, all pages are printable.

Print Quality

Resolution:

High-resolution, suitable for clear viewing and printing of diagrams and text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Requirements

Software:

Adobe Reader (or compatible PDF viewer)

Compatibility:

Windows, Mac, and Linux operating systems

File Organization

Searchability:

Likely offers searchable text within the PDF for quick access to specific information.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.2 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.7:1

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Fuel System:

Electronic Sequential Port Fuel Injection (ESPFI)

Performance

Horsepower:

Approximately 67 hp @ 5800 rpm (figures may vary slightly based on tuning and specific market).

Torque:

Approximately 70 ft-lbs @ 3500 rpm (figures may vary slightly based on tuning and specific market).

Fuel System

Fuel Tank Capacity:

3.1 gallons (11.7 L)

Lubrication System

Oil Type Specification:

Refer to manual for specific Harley-Davidson approved oils (typically SAE 20W50 for air-cooled V-twins).

🔧 Transmission

Standard

Type:

5-speed manual

Primary Drive:

Clutch, chain drive to transmission

Final Drive:

Belt drive

Features

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Length:

Approximately 88.5 inches (2248 mm)

Width:

Approximately 32.5 inches (826 mm)

Height:

Approximately 49.0 inches (1245 mm)

Weights

Dry Weight:

Approximately 571 lbs (259 kg)

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle compliance plate; typically around 960 lbs (435 kg).

Wheelbase

Wheelbase:

Approximately 60.0 inches (1524 mm)

Ground Clearance

Ground Clearance:

Approximately 4.4 inches (112 mm)

🛡️ Safety Features

Ratings

Safety Certification:

Compliant with relevant national motorcycle safety standards (e.g., DOT, ECE as applicable by market).

Active Features

Braking System:

Dual-piston front and rear brake calipers with hydraulic actuation.

Passive Features

Lighting:

Halogen headlamp, LED tail light, amber turn signals.

Precautions

Use Of Tools:

Emphasizes the critical importance of using correct Harley-Davidson specified special service tools to avoid damage and ensure safety.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer with integrated digital odometer, tachometer, fuel gauge, and indicator lights. May include optional Harley-Davidson factory installed audio systems on some variants.

Driver Assistance

Anti-lock Braking System (ABS) was often an optional feature for the 2010 XL1200R, details are specific to the vehicle's configuration.

Connectivity

Diagnostic Port:

Features a diagnostic port for connecting Harley-Davidson proprietary diagnostic tools for fault code retrieval and system analysis.

🔧 Maintenance

Service Intervals

First Service:

Typically at 1,000 miles (1600 km) or 6 months, whichever comes first, covering oil change, filter replacement, and critical component checks.

Subsequent Service:

Regularly scheduled maintenance every 5,000 miles (8,000 km) or 12 months, including engine oil and filter changes, inspection of various systems, and adjustments.

Fluid Specifications

Engine Oil Capacity:

Approximately 3.0 US quarts (2.8 L) with filter change. Refer to manual for exact specification and procedure.

Transmission Oil Type:

Harley-Davidson recommended primary chaincase lubricant (e.g., Formula+).

Brake Fluid Type:

DOT 4 synthetic brake fluid.

Known Issues

Common Wear Items:

Clutch friction plates, brake pads, fork seals, wheel bearings, and drive belt are common wear items requiring periodic inspection and replacement.

Electrical Connections:

Corrosion or looseness in electrical connectors can occasionally lead to intermittent issues; regular inspection is advised.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and the 'Harley-Davidson lifestyle'.

Model Evolution

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running motorcycle model. The XL1200R represents a modern iteration of this classic platform, focusing on performance-oriented variants.

Production

Manufacturing Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Model Standing:

While specific awards for the 2010 XL1200R may not be widely publicized, the Sportster platform is consistently recognized for its blend of classic styling, performance, and customizability within the cruiser segment.