🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C

Year:

2009

Series:

Sportster Custom

Model Code:

XL1200C

Engine Code:

Evolution V-Twin (Air-Cooled)

👋 Introduction

Positioning:

The Harley-Davidson XL1200C (Sportster Custom) is a popular cruiser motorcycle, known for its classic styling, accessible performance, and customization potential. It appeals to riders seeking a stylish and iconic V-twin experience.

Competitors:

Competes with other mid-weight cruisers from brands like Indian, Triumph, and Japanese manufacturers offering similar displacement and cruiser styling.

Styling:

Iconic Sportster design, often featuring chrome accents, a comfortable riding position, and a classic silhouette.

Engine:

Harley-Davidson's renowned Evolution V-twin engine, known for its torque and distinctive sound.

Customization:

Highly popular for customization, with a vast aftermarket of parts and accessories available.

📋 Manual Details

Primary Focus:

Repair, Maintenance, Troubleshooting, and Diagnostics

Scope:

Comprehensive Workshop Service

Total Pages:

846

Type:

Workshop Service Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Complete overhaul, disassembly, assembly, troubleshooting of Evolution V-Twin engine (carbureted and fuel-injected variants relevant to 2009 model year).

Transmission:

5-speed constant mesh transmission, clutch, shift mechanism, lubrication, disassembly, and assembly procedures.

Drivetrain:

Belt drive system, primary drive, rear drive belt inspection and replacement.

Fuel System:

Carburetor (Keihin CV 40) or Electronic Fuel Injection (EFI) system, fuel pump, fuel tank, fuel lines, and associated sensors.

Ignition System:

Electronic ignition system, coil, spark plugs, ignition module diagnostics.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), horn, instrumentation, wiring diagrams, troubleshooting.

Suspension:

Front fork (telescopic) overhaul, fluid replacement, seal replacement, rear shock absorbers, mounting points.

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, bleeding procedures.

Wheels Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, spoke tensioning (if applicable).

Frame Chassis:

Frame inspection, steering head bearings, swingarm, mounting hardware torque specifications.

Bodywork:

Fenders, fuel tank, seat, handlebars, controls, fairings (if equipped), trim, and related hardware.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs) for EFI models, common problem identification.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, chain/belt adjustment and lubrication, brake pad checks, tire pressure.

Major Repairs:

Engine rebuilding, transmission overhauls, suspension component replacement, brake caliper rebuilds, electrical component diagnosis and replacement.

Troubleshooting:

System-by-system troubleshooting guides for common and uncommon issues, including starting problems, performance issues, and electrical faults.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Torque Specifications:

Detailed torque values for all critical fasteners and components.

Wiring Diagrams:

Complete and detailed electrical wiring schematics for all model variations.

Depth Level:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostics for EFI systems, including sensor data interpretation and troubleshooting of electronic control modules (ECMs).

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text within the PDF for easy navigation.

Quality:

Digital, providing clear and legible text and diagrams.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.500 in. x 3.812 in. (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Valve Train:

Pushrod-actuated, overhead valves (OHV), 2 valves per cylinder

Cooling System:

Air-cooled

Horsepower:

Approx. 66 HP @ 5800 RPM (estimated, actual may vary)

Torque:

Approx. 79 ft-lbs @ 3500 RPM (estimated, actual may vary)

Fuel Delivery:

Keihin CV 40mm Constant Velocity carburetor OR Electronic Sequential Port Fuel Injection (ESPFI) - Model year 2009 could be either depending on market or specific sub-model.

Fuel Capacity:

3.0 gallons (11.4 liters)

Fuel Type:

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

🔧 Transmission

Type:

5-speed, constant mesh

Clutch:

Multi-plate, wet

Primary Drive:

Plated, wet, multi-plate, chain drive

Final Drive:

Belt drive, 25mm width

📐 Dimensions

Length:

88.5 in. (2248 mm)

Width:

34.1 in. (866 mm)

Height:

47.2 in. (1200 mm)

Wheelbase:

60.0 in. (1524 mm)

Ground Clearance:

4.75 in. (120 mm)

Seat Height:

26.5 in. (673 mm) (unladen)

Dry Weight:

575 lbs (261 kg)

Gross Vehicle Weight Rating:

930 lbs (422 kg)

Payload Capacity:

355 lbs (161 kg)

🛡️ Safety Features

NHTSA Rating:

N/A (Motorcycles are not typically rated by NHTSA in the same manner as passenger cars)

Brakes:

Hydraulic disc brakes front and rear.

Lighting:

Halogen headlight, LED taillight and stoplight, front and rear amber incandescent turn signals.

Frame:

Steel tubular frame and swingarm.

Ride Position:

Ergonomic rider triangle designed for comfort on longer rides.

💡 Technology Features

Display:

Analog speedometer with integrated digital odometer, tachometer (often optional or part of a separate gauge on base models).

Audio:

Typically no integrated audio system on this model; aftermarket solutions are common.

ABS:

Anti-lock Braking System (ABS) was an optional feature for the 2009 XL1200C. The manual would cover its functionality and maintenance if equipped.

Usb:

No factory USB or Bluetooth connectivity on this model; aftermarket integration is common.

🔧 Maintenance

Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Primary Chain Tensioner:

Inspect every 10,000 miles (16,000 km).

Spark Plugs:

Inspect every 10,000 miles (16,000 km), replace as needed.

Drive Belt:

Inspect for wear and tension every 5,000 miles (8,000 km).

Brake Fluid:

Flush and replace every 2 years (DOT 4 recommended).

Fork Oil:

Replace every 2 years or 20,000 miles (32,000 km).

Engine Oil:

Harley-Davidson SYN3 (20W50 Synthetic) or equivalent motorcycle-specific oil meeting Harley-Davidson specifications.

Primary Chain Case Oil:

Harley-Davidson primary oil or SAE 50 motorcycle oil.

Transmission Oil:

Harley-Davidson transmission oil or SAE 85W-140 gear oil.

Brake Fluid:

DOT 4 Hydraulic Fluid.

Primary Chain Tensioner:

Early models (pre-2007) had a known issue with the spring-loaded tensioner being replaced by a hydraulic one. For 2009, the hydraulic tensioner is standard, but it's still an area to monitor for wear or potential leaks.

Carburetor Vs Efi:

If the model is carbureted, owners might experience occasional tuning issues or need for carburetor cleaning/rebuilding. EFI models are generally more stable but require specialized diagnostic tools.

Suspension Seals:

Front fork seals can sometimes leak, requiring replacement. This is common maintenance for many motorcycles.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of producing V-twin powered motorcycles known for their sound, style, and community.

Sportster Lineage:

The Sportster line dates back to 1957, evolving through various displacements and configurations. The XL1200 models represent a significant step in performance and refinement for the series.

Xl1200C Custom:

The 'C' designation signifies the 'Custom' model, typically featuring enhanced styling elements, a more comfortable seat, and often a larger front wheel compared to other Sportster variants of the era.

Production Years:

The XL1200C has been in continuous production for many years, with the 2009 model being part of a well-established generation.

🏆 Awards & Recognition

Segment Awards:

The Sportster line, including the XL1200C, has consistently received praise from motorcycle publications for its styling, customization potential, and accessible V-twin experience within its segment.

Reliability Reputation:

Generally considered reliable with proper maintenance. The Evolution engine is known for its durability.