Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners seeking to perform their own maintenance and repairs, independent repair shops
Positioning:
The XL1200C Sportster Custom offers a classic Harley-Davidson riding experience with modern fuel injection and a potent V-twin engine, appealing to riders seeking style and performance.
Distinctive Elements:
Iconic Sportster styling, ample chrome, comfortable riding position, and the characteristic rumble of a Harley-Davidson V-twin.
Engine Service:
Engine disassembly, assembly, tuning, troubleshooting, and component testing
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel tank, lines, and regulators
Ignition System:
Ignition module, spark plugs, coils, wiring, and timing adjustments
Transmission And Drivetrain:
Clutch, primary drive, transmission gears, shifting mechanisms, final drive belt inspection and replacement
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system, lighting, instruments, and accessories
Brake System:
Front and rear brake calipers, master cylinders, lines, pads, rotors, and hydraulic system bleeding
Suspension And Steering:
Front forks (disassembly, service, fluid replacement), rear shock absorbers, steering head bearings, and wheel alignment
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, and exhaust system
Wheels And Tires:
Wheel bearing service, tire inspection and replacement, spoke tensioning (if applicable)
Exhaust System:
Removal, installation, and inspection of exhaust components.
Cooling System:
Air-cooled engine, but manual covers heat management principles and related components.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain/belt adjustments, lubrication points
Troubleshooting Guides:
Diagnostic charts for common performance issues and failures
Component Rebuild:
Detailed instructions for overhauling engines, transmissions, and other major components
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Torque Specifications:
Precise torque values for all fasteners and critical components
Torque Tables:
Detailed tables for all critical fasteners, essential for safe and correct assembly.
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and advanced diagnostics)
Diagnostic Procedures:
Includes troubleshooting flowcharts and diagnostic codes for EFI and electrical systems.
Official Designation:
Factory Service Manual
Engine Type:
Evolution V-Twin, Air-Cooled
Displacement:
1200cc (73.2 cu. in.)
Bore X Stroke:
3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)
Horsepower:
Approx. 65-70 HP (estimated, varies by dyno and specific tuning)
Torque:
Approx. 67-70 ft-lbs @ 3500 RPM (estimated, varies by dyno and specific tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
91 octane or higher recommended
Oil Type:
Harley-Davidson Genuine V-Twin Motor Oil or equivalent SAE 20W50
Oil Capacity:
3.5 US qt (3.3 L) with filter change
Instrumentation:
Analog speedometer, tachometer (optional/integrated), odometer, trip meter, fuel gauge, indicator lights.
ABS:
Not standard for the 2008 model year.
Diagnostic Tools:
Requires Harley-Davidson specific diagnostic tools (e.g., Digital Technician) for advanced electronic diagnostics.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
5,000 miles (8,000 km) or 12 months (whichever comes first)
Engine Oil Change:
Every 5,000 miles (8,000 km) or 12 months
Fork Oil Type:
Harley-Davidson® front fork oil (specify weight as per manual)
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for specific recommendation)
Common Wear Items:
Clutch friction plates, brake pads, drive belt, suspension seals.
Potential Electrical Concerns:
Occasional issues with charging system components (regulator/rectifier) or wiring harness integrity over time.
Engine Tuning:
May require periodic re-mapping or adjustment of EFI for optimal performance and emissions compliance, especially with aftermarket modifications.
