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Harley Davidson XL1200C 2009 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Year: 2009 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Vehicle Segment: Cruiser Motorcycle Target Audience: Enthusiasts, owners, and professional...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL1200C
Year:
2009
Product Type:
Service Repair Workshop Manual
👋 Introduction
Market Position
Vehicle Segment:
Cruiser Motorcycle
Target Audience:
Enthusiasts, owners, and professional mechanics working on Harley-Davidson XL1200C models.
Competitive Analysis
Competitors:
Other cruiser motorcycles of similar displacement from brands like Indian, Victory, and some Japanese manufacturers.
Key Features
Vehicle Appeal:
Iconic styling, V-twin engine character, customization potential, strong brand loyalty.
Manual Value Proposition:
Provides essential, factory-authorized information for maintaining and repairing the specific model, ensuring longevity and performance.
📋 Manual Details
Coverage Areas
Engine Service:
Complete
Transmission Service:
Complete
Chassis Service:
Complete
Electrical System:
Complete
Fuel System:
Complete
Brake System:
Complete
Suspension System:
Complete
Bodywork And Frame:
Complete
Troubleshooting:
Comprehensive Diagnostic Procedures
Page Count
Estimated Pages:
Approximately 500-700 (typical for this model/type)
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, though physical may exist)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, assembly, inspection, repair of cylinders, pistons, crankshaft, camshafts, valves, and timing.
Fuel And Ignition:
Carburetor (if applicable for the specific model variant, though 2009 XL1200C likely has fuel injection) or EFI system, fuel pump, injectors, ignition system, spark plugs, ignition timing.
Exhaust System:
Mufflers, pipes, catalytic converter (if equipped), and mounting.
Transmission And Drivetrain:
Clutch operation, gearbox disassembly and assembly, primary drive, final drive (belt drive).
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, ignition switch, security system.
Brake System:
Front and rear brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.
Suspension And Steering:
Front fork (telescopic) overhaul, rear shock absorber replacement, steering head bearings.
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing, spoke wheel maintenance (if applicable).
Frame And Bodywork:
Frame inspection, fuel tank removal and installation, fenders, seat, handlebars, controls.
Procedures Included
Maintenance:
Routine checks, lubrication, filter replacement, fluid changes, spark plug replacement, belt tension adjustment.
Diagnostics:
Troubleshooting charts for common problems, fault code retrieval (if applicable to EFI), component testing.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Overhaul:
Complete engine, transmission, and fork overhauls.
Adjustments:
Clutch adjustment, throttle cable adjustment, brake lever adjustment.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and electrical system diagnostics.
Detail Level:
Includes detailed diagrams, exploded views, torque specifications, and diagnostic flowcharts.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - assumed for digital versions. Enables searchability and easy navigation.
Print Quality
Quality:
High resolution scans or original digital files, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (for digital); Professional perfect binding or lay-flat spiral binding (for physical reprints).
Paper Type
Paper:
N/A (for digital); High-quality, durable paper stock suitable for workshop environments (for physical reprints).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Evolution V-Twin
Displacement:
1200cc (73.3 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio:
9.7:1
Valve Train:
Overhead Valves (OHV) with pushrods, 2 valves per cylinder
Performance
Horsepower:
Approximately 65-70 HP (estimated, actual figures vary)
Torque:
Approximately 70-75 lb-ft (estimated, actual figures vary)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) - Standard for 2009 XL1200C
Fuel Type:
Unleaded gasoline, minimum 91 octane (RM)
Cooling System
Type:
Air-cooled
🔧 Transmission
Standard
Transmission Type:
5-speed, Cruise Drive
Primary Drive:
Chain, 34/46 ratio
Final Drive:
Belt, 29/68 ratio
Features
Clutch Type:
Wet, multi-plate
Transmission Fluid Type:
Harley-Davidson SYN3 (or equivalent motorcycle specific transmission oil)
📐 Dimensions
Exterior
Length:
90.4 in (2296 mm)
Seat Height Laden:
26.3 in (668 mm)
Ground Clearance:
4.3 in (109 mm)
Weights
Dry Weight:
573 lb (260 kg)
Gross Vehicle Weight Rating:
939 lb (426 kg)
Fuel Capacity:
4.5 gal (17.0 L)
🛡️ Safety Features
Ratings
Crash Safety:
Motorcycles are not typically subject to standardized crash ratings like automobiles. Safety relies on design, rider skill, and protective gear.
Active Features
Brakes:
Dual-action, front and rear disc brakes.
Lighting:
Halogen headlamp, LED taillight, front and rear turn signals.
Passive Features
Frame Construction:
Steel frame and swingarm construction.
Ergonomics:
Designed for rider comfort and control, with forward-mounted controls and a low seat height.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, fuel gauge, indicator lights. Often includes a trip odometer and clock.
Audio System:
Not typically standard on this model. Aftermarket audio systems are common.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on many Harley-Davidson models, including the XL1200C for this year. Availability would depend on the specific bike's configuration.
Connectivity
Security System:
Factory-installed H-D Smart Security System with proximity-based fob is often standard or optional.
🔧 Maintenance
Service Intervals
Initial Service:
Approximately 1,000 miles (1,600 km) - typically includes oil change, primary chain adjustment, inspection.
Subsequent Service:
Every 5,000 miles (8,000 km) or annually - includes engine oil and filter change, check belt tension, inspect brakes, chassis lubrication, etc.
Major Service Intervals:
Refer to manual for specific intervals for valve adjustments, spark plug replacement, and other major component checks.
Fluid Specifications
Engine Oil:
Harley-Davidson SYN3 (20W-50) or equivalent motorcycle-specific oil meeting HD-2 specification.
Primary Chain Case Fluid:
Harley-Davidson SYN3 (20W-50) or HD-1 specification motorcycle oil.
Transmission Fluid:
Harley-Davidson SYN3 (20W-50) or equivalent motorcycle specific transmission oil.
Brake Fluid:
DOT 4.
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, drive belt, fork seals, wheel bearings.
Potential Issues:
EFI sensor issues (e.g., Throttle Position Sensor, Manifold Absolute Pressure Sensor), voltage regulator failure, early model transmission seal leaks (though less common by 2009).
📚 Vehicle History
Brand Heritage
Brand History:
Harley-Davidson is an iconic American motorcycle manufacturer with a history dating back to 1903, renowned for its V-twin engines and cruiser styling.
Model Evolution
Sportster Lineage:
The XL series, or 'Sportster', is one of Harley-Davidson's longest-running model lines, evolving from a sporty, lightweight machine to a more substantial cruiser.
Xl1200C Evolution:
The XL1200C Custom model, introduced in the mid-1990s, focused on classic styling cues like chrome, spoked wheels, and a lower seat height, becoming a popular configuration.
Production
Manufacturing Location:
United States (primarily Kansas City, Missouri and York, Pennsylvania)
Key Updates 2009:
The 2009 model year saw updates including potentially revised styling, improved EFI calibration, and possibly minor chassis or suspension tweaks. The manual would reflect these specific changes.
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Harley-Davidson Sportster line, including the XL1200C, is consistently recognized for its styling, performance, and customization potential, often appearing on 'best cruiser' lists.
Certifications
Compliance:
Meets all applicable US EPA and California Air Resources Board (CARB) emissions standards for its model year.