Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson XL1200C Sportster Custom owners, independent mechanics, and motorcycle enthusiasts seeking detailed repair and maintenance information.
Comparison:
The XL1200C represents a classic American cruiser experience, known for its accessible seat height, classic styling, and V-twin rumble. This manual provides the essential technical documentation for maintaining and repairing this iconic model.
Manual Value:
Provides authorized factory procedures and specifications, ensuring correct maintenance and repair, crucial for preserving the value and performance of a Harley-Davidson.
Model Appeal:
The XL1200C is a popular choice for its blend of classic Harley-Davidson styling and manageable size, making it a favorite for both new and experienced riders.
Engine Mechanical:
Engine removal/installation, cylinder head, cylinders, pistons, connecting rods, crankshaft, camshafts, oil pump, primary drive system, clutch, transmission, final drive.
Fuel System:
Fuel tank, fuel pump, fuel injectors, throttle body, fuel pressure regulator, fuel lines, evaporative emission control system.
Ignition System:
Ignition module, ignition coil, spark plugs, wiring.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlamp, tail lamp, turn signals), instrumentation, horn, wiring diagrams, fuses, relays.
Chassis Components:
Frame, front suspension (forks, triple clamps), rear suspension (shock absorbers, swingarm), steering system, front and rear brakes (calipers, rotors, master cylinders, lines), wheels, tires.
Bodywork And Fittings:
Fenders, fuel tank, seat, handlebars, controls, mirrors, exhaust system, side covers, any accessory mounting.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacement, lubrication points, chain adjustment (if applicable), brake fluid replacement, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation, electrical system diagnostics, engine performance problems.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Installation:
Instructions for installing new or replacement parts and accessories.
Depth:
Comprehensive; covers everything from basic rider maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and chassis component overhauls.
Searchable:
Typically searchable (dependent on original PDF creation)
Printability:
Printable (allows users to print entire manual or selected sections)
Binding:
N/A (Digital download - printing by user)
Paper Type:
N/A (Digital download - paper type is user's choice)
Completeness:
This is the complete official factory service manual, covering all aspects of the vehicle's operation, maintenance, and repair, allowing for full rebuilds and in-depth diagnostics.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200 cc (73.3 cubic inches)
Bore X Stroke:
3.500 in. x 3.812 in. (88.9 mm x 96.8 mm)
Compression Ratio:
9.7:1 (Typical for Evolution 1200)
Horsepower:
Approximately 65-70 HP (Estimate, specific rating may vary)
Torque:
Approximately 70-75 ft-lbs (Estimate, specific rating may vary)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 89 octane (87 AKI or higher recommended)
Crash Test Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA in the same way as cars).
Braking System:
Dual-action front and rear disc brakes with hydraulic actuation. Dual-piston front caliper, single-piston rear caliper.
Lighting:
Halogen headlamp, LED tail lamp, amber front and rear turn signals.
Frame Construction:
Steel, welded, integral unit.
Tires:
Front: 100/90-19 57H, Rear: 150/80B16 77H (Typical fitment, manual confirms specifics)
Instrumentation:
Analog speedometer, tachometer (often optional or part of a combination display), odometer, trip meter, gear indicator, fuel gauge, and indicator lights.
Features:
No electronic driver assistance systems common in automobiles (e.g., ABS, traction control) were standard on this model. ABS was an optional feature and would be detailed in the manual if equipped.
Features:
No advanced connectivity features like Bluetooth or smartphone integration.
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first). Manual provides detailed checklist.
Subsequent Service:
Typically every 5,000 miles (8,000 km) or 12 months thereafter. Manual will detail specific interval checks.
Engine Oil:
Harley-Davidson Genuine V-Twin Motorcycle Oil SAE 20W-50 or equivalent (e.g., synthetic SAE 20W-50). Manual specifies precise API classification and quantity.
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Case Oil or SAE 90 Hypoid Gear Oil. Manual specifies quantity and checking procedure.
Transmission Oil:
Harley-Davidson Genuine Formula SAE 80W-90 Sportbike Gear Oil or equivalent. Manual specifies quantity.
Brake Fluid:
DOT 4 Heavy Duty Motor Vehicle Brake Fluid (non-silicone based). Manual specifies quantity and replacement interval.
Common Complaints:
Manual will assist in diagnosing potential issues such as charging system problems (regulator/stator), occasional oil leaks, clutch drag, or fuel system sensor errors.
Preventative Maintenance:
The manual emphasizes diligent adherence to maintenance schedules to prevent common wear-related issues.
Legacy:
Harley-Davidson boasts a rich heritage dating back to 1903, synonymous with American motorcycling culture and custom chopper aesthetics.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. The XL1200C 'Custom' variant typically features a longer wheelbase, lower seat height, and more chrome than its siblings, emphasizing its classic cruiser styling.
Manufacturing Origin:
United States
2009 Model Context:
The 2009 model year was part of the evolution of the Sportster platform, incorporating electronic fuel injection and other updates for performance and emissions compliance.
