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Harley XL1200C Sportster Custom 2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Year: 2002 Product Name: Harley XL1200C Sportster Custom 2002 Service Repair Manual Product Type: Service Repair Manual 👋 Introduction Market...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL1200C Sportster Custom
Year:
2002
Product Name:
Harley XL1200C Sportster Custom 2002 Service Repair Manual
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle
Target Audience:
Owners of the 2002 Harley-Davidson XL1200C Sportster Custom seeking to perform maintenance and repairs.
Competitive Analysis
Original Manual Provider:
Harley-Davidson Motor Company
Key Features
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.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair and maintenance for the 2002 Harley-Davidson XL1200C Sportster Custom.
Page Count
Estimated Page Count:
500-700 pages (typical for this era and model)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
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.
Procedures Included
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.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Suitable for DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable Text:
Yes (typical for well-digitized PDFs)
Print Quality
Printability:
Printable on standard home or office printers.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
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)
Compression Ratio:
8.8:1
Performance
Horsepower Est:
Approx. 60-65 HP (at crank)
Torque Est:
Approx. 67-70 ft-lbs (at crank)
Fuel System
Carburetor Model:
Keihin CV (Constant Velocity)
Fuel Delivery:
Carbureted
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication
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)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain
Final Drive:
Belt drive
Features
Clutch Type:
Wet, multi-plate
Transmission Oil Type:
Harley-Davidson transmission lubricant or equivalent
Transmission Oil Capacity:
24 US fl oz (0.71 L)
📐 Dimensions
Exterior
Length:
90.1 in (2289 mm)
Width:
35.2 in (894 mm)
Height:
47.4 in (1204 mm)
Wheelbase:
60.0 in (1524 mm)
Ground Clearance:
4.4 in (112 mm)
Weights
Dry Weight:
538 lbs (244 kg)
Gross Vehicle Weight Rating:
965 lbs (438 kg)
Fuel Capacity:
4.0 US gal (15.1 L)
Oil Capacity:
3.0 US qt (2.8 L)
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable for motorcycles in the same way as automobiles; adheres to relevant motorcycle safety standards.
Active Features
Braking System:
Dual hydraulic disc brakes (front and rear) with single-piston calipers.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Passive Features
Frame Construction:
Steel frame for rigidity and rider protection.
Rider Controls:
Ergonomically placed handlebars and foot controls for rider command.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No integrated infotainment system; relies on aftermarket audio or communication devices).
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance features common in modern vehicles).
Connectivity
Connectivity Features:
N/A (No built-in Bluetooth, USB, or smartphone integration).
Instrumentation
Instrument Cluster:
Analog speedometer, tachometer (optional on some models), odometer, trip meter, engine oil pressure warning light, turn signal indicators, high beam indicator.
🔧 Maintenance
Service Intervals
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).
Fluid Specifications
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).
Known Issues
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.
📚 Vehicle History
Brand Heritage
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.
Model Evolution
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.
Production
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.
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
While specific awards for the 2002 model might be limited, the Harley-Davidson Sportster line has a long-standing reputation and is widely recognized as an iconic American motorcycle.
Ratings
Customer Satisfaction:
High customer satisfaction for its classic styling, V-twin rumble, and customization potential.