Positioning:
The Sportster 1200 Custom (XL1200C) is positioned as a stylish, classic cruiser offering a balance of performance and iconic Harley-Davidson styling, catering to riders seeking a versatile urban and touring machine.
Competition:
Competes with other American V-twin cruisers and some Japanese retro-styled motorcycles, emphasizing customization and the Harley-Davidson ownership experience.
Features Highlight:
Chrome-laden styling, forward-mounted foot controls, swept-back handlebars, iconic Evolution engine, custom 1200cc displacement, and broad customization potential.
Overall Coverage:
Comprehensive service and repair for the 2010 Harley-Davidson Sportster 1200 Custom (XL1200C).
Key Systems:
Engine, transmission, drivetrain, chassis, electrical system, brakes, suspension, fuel system, exhaust system, bodywork, diagnostics.
Estimated Pages:
Hundreds (typical for a full service manual)
Type:
Service Repair Manual
Format:
Instant Download (likely PDF)
Engine Mechanical:
Detailed coverage of 1200cc Evolution V-Twin engine, including disassembly, inspection, assembly, timing, valve adjustment, and cylinder head service.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body service, fuel pressure testing, and troubleshooting.
Transmission Drivetrain:
5-speed transmission, clutch operation, primary drive, belt drive system, and final drive maintenance.
Electrical System:
Wiring diagrams, battery service, charging system (stator, regulator/rectifier), ignition system, lighting, starter, and accessory circuits.
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications, and bleeding procedures.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber maintenance, and alignment checks.
Chassis Frame:
Frame inspection, steering head bearing service, wheel bearing maintenance, and general chassis component checks.
Bodywork Cosmetics:
Fairing, fenders, fuel tank, seat, and minor body panel removal and installation procedures.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake pad inspection, chain/belt adjustment.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and braking issues. Symptom-based troubleshooting guides.
Repair Rebuild:
Detailed instructions for engine, transmission, brake system, and electrical component repairs and rebuilds.
Diagnostics:
Information on diagnostic codes (if applicable to the 2010 model's EFI system), sensor testing, and reading error codes.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission overhauls. Includes detailed torque specifications and clearances.
File Type:
PDF (Portable Document Format) likely, offering searchability and easy printing.
Quality:
High-resolution, with clear diagrams and legible text.
Binding:
Not applicable for instant download (digital format).
Paper:
Not applicable for instant download (digital format).
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.2 cu in)
Bore X Stroke:
3.5 in x 3.81 in (88.9 mm x 96.8 mm)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Engine Oil Capacity:
Approx. 3.0 US qt (2.8 L)
Engine Oil Type:
Harley-Davidson Genuine Motor Oil SAE 20W50 (or equivalent)
Engine Oil Filter Pn:
63731-97 (or equivalent)
Horsepower:
Approx. 67 HP @ 5750 RPM (manufacturer spec may vary, actual output depends on conditions)
Torque:
Approx. 72 ft-lb @ 3500 RPM (manufacturer spec may vary, actual output depends on conditions)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 or higher recommended
Crash Test Ratings:
Motorcycles are not typically rated by organizations like NHTSA or IIHS in the same way cars are. Safety relies on rider skill and adherence to safe riding practices.
Active Safety:
Disc brakes (front and rear) for stopping power. Some models may have optional ABS.
Passive Safety:
Sturdy steel frame, rider control through ergonomics, and lighting for visibility.
Infotainment Features:
Base models typically feature analog gauges (speedometer, tachometer). Advanced infotainment systems were not standard on the 2010 XL1200C, but some aftermarket integration is possible.
Assistance Features:
ABS was an optional feature for the 2010 model year.
Connectivity Features:
No built-in smartphone connectivity or advanced electronic rider aids standard on this model. Primarily mechanical and basic electrical systems.
First Service:
1,000 miles (1,600 km) or 12 months, whichever comes first (typically includes oil change, filter, check belts, etc.)
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months for oil changes and inspections. More intensive checks like valve adjustments and spark plug replacement typically at 10,000 or 15,000-mile intervals, as detailed in the service manual.
Engine Oil:
Harley-Davidson Genuine Motor Oil SAE 20W50
Transmission Primary Fluid:
Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant
Brake Fluid:
DOT 4 (or specified by Harley-Davidson for the 2010 model)
Common Wear Items:
Clutch wear, fork seal leaks, rear belt wear, battery degradation, exhaust gasket leaks, and occasional EFI sensor issues.
Maintenance Importance:
Regular maintenance is crucial for the longevity and performance of the Evolution engine and the overall reliability of the motorcycle, especially considering the V-twin's vibration characteristics.
Brand History:
Harley-Davidson, founded in 1903, boasts a rich legacy in American motorcycling, synonymous with V-twin engines, cruiser styling, and a distinct rider culture.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. The 1200cc Evolution engine, introduced in 1988, has been a staple in the Sportster family, continually refined.
Xl1200C Specifics:
The XL1200C 'Custom' variant emerged as a popular configuration, emphasizing chrome, custom paint options, and rider-friendly ergonomics for a classic cruiser look and feel.
Production Location:
United States (Milwaukee, Wisconsin, and Kansas City, Missouri, historically for Sportster models)
