Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners and independent mechanics seeking detailed repair and maintenance information.
Manual Value Proposition:
Comprehensive, officially sanctioned information for DIY repairs, saving on dealership service costs.
Vehicle Focus:
Custom styling with a powerful V-twin engine, a hallmark of Harley-Davidson's Sportster line.
Manual Benefit:
Empowers owners with the knowledge to maintain and repair their motorcycle, preserving its value and performance.
Engine Systems:
Engine assembly, disassembly, tuning, lubrication, cooling (air-cooled), fuel delivery (carburetor), ignition system, exhaust system, performance modifications.
Transmission Drivetrain Systems:
Clutch, primary drive, transmission case, gears, shifting mechanism, final drive (belt drive), lubrication.
Chassis Frame Systems:
Frame, swingarm, steering head bearings, front forks (telescopic), rear shock absorbers, wheel bearings, suspension adjustments.
Braking Systems:
Front and rear brake systems (hydraulic disc), brake calipers, master cylinders, brake lines, fluid types, bleeding procedures.
Electrical Systems:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting system (headlight, taillight, turn signals), starter system, wiring diagrams, fuses, relays, switches.
Fuel System:
Fuel tank, fuel lines, carburetor (Keihin CV), air cleaner, fuel shut-off valve.
Bodywork Fittings:
Fenders, fuel tank, seat assembly, handlebars, controls, footpegs, exhaust system mounting, chrome trim.
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, chain adjustment, brake fluid flush, tire pressure checks, battery maintenance, carburetor cleaning and adjustment.
Repair Procedures:
Engine rebuilds, transmission overhaul, fork seal replacement, brake caliper rebuild, electrical component troubleshooting and replacement, carburetor jetting, exhaust system replacement.
Troubleshooting Diagnostics:
Common issues, diagnostic charts, fault finding for engine, electrical, and mechanical problems.
Diagnostic Capabilities:
Advanced diagnostics for engine performance issues, electrical faults, and mechanical wear.
Rebuild Instructions:
Complete, step-by-step instructions for engine, transmission, and other major component overhauls.
Special Tools:
Identification and usage of Harley-Davidson specific tools required for various procedures.
Engine Type:
Air-cooled, Evolution (Evo) V-twin
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Valvetrain:
Overhead valves (OHV), two valves per cylinder, pushrod actuated.
Horsepower Approx:
Approx. 60-65 HP (estimated, not officially stated for 2002)
Torque Approx:
Approx. 65-70 lb-ft (estimated, not officially stated for 2002)
Fuel Delivery:
Carburetor (Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
3.5 gallons (13.2 L)
Ignition Type:
Electronic, spark ignition
Oil Capacity:
3.0 US qt (2.8 L) with filter change
Oil Type Specification:
Harley-Davidson SYN3 or equivalent V-Twin motorcycle oil, SAE 20W50
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain, wet clutch
Final Drive:
Belt drive, 132-tooth rear belt
Clutch Type:
Wet, multi-plate
Gear Ratios:
1st: 10.110, 2nd: 6.570, 3rd: 4.750, 4th: 3.760, 5th: 3.160
Transmission Oil Capacity:
24 US fl oz (0.71 L)
Transmission Oil Type:
Harley-Davidson Transmission and Primary Chaincase Lubricant or equivalent, SAE 80W-90 GL-5
Engine Oil Change:
Every 2,500 miles (4,000 km) or 6 months, whichever comes first.
Primary Chaincase Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months, whichever comes first.
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Belt Tension Check Adjustment:
Every 2,500 miles (4,000 km)
Engine Oil Specification:
Harley-Davidson SYN3 or equivalent V-Twin motorcycle oil, SAE 20W50
Transmission Oil Specification:
Harley-Davidson Transmission and Primary Chaincase Lubricant or equivalent, SAE 80W-90 GL-5
Brake Fluid Specification:
DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Clutch plates, belt drive wear, fork seals, wheel bearings, ignition coils (depending on specific manufacturing batch).
Electrical Gremlins:
Occasional issues with charging system components (regulator/rectifier) and wiring harness integrity over time.
Carburetor Tuning:
Requires periodic adjustment and cleaning for optimal performance, especially after long storage or modifications.
Brand Identity:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser styling.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model. The XL1200C 'Custom' variant typically features enhanced styling elements like a larger front wheel, different handlebars, and often chrome accents.
Manufacturing Location:
USA (Milwaukee, Wisconsin)
