Harley Davidson Sportster 1200 2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster 1200 Year: 2009 Family: Sportster Codes Vin Prefix: 1HD1 👋 Introduction Market Position Market Segment: Cruiser motorcycle segment, targeting riders seeking classic...

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类型: Motorcycle

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标签: 2009 Harley Davidson Misc Motorcycle Motorcycles Sportster 1200

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster 1200

Year:

Family:

Sportster

Codes

Vin Prefix:

👋 Introduction

Market Position

Market Segment:

Cruiser motorcycle segment, targeting riders seeking classic styling and V-twin performance.

Competitive Analysis

Key Competitors 2009:

Indian Chief, Triumph Bonneville, Yamaha V-Star, Kawasaki Vulcan, Honda Shadow.

Key Features

Engine Layout:

Iconic air-cooled Evolution V-Twin engine, known for its torque and distinctive sound.

Chassis Design:

Classic Sportster rigid frame, contributing to its agile handling and iconic silhouette.

Customization Potential:

High degree of customization inherent in the Harley-Davidson platform, appealing to riders who personalize their bikes.

📋 Manual Details

Coverage Areas

Model Variant Coverage:

All 2009 Harley-Davidson Sportster 1200 models (e.g., XL1200C Custom, XL1200L Low, XL1200N Nightster, XL1200R Roadster)

Page Count

Estimated Page Count:

Approximately 600-800 pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

V-Twin Evolution engine, including disassembly, assembly, diagnosis, and repair of all internal and external components.

Fuel System:

Fuel injection (EFI) system, throttle body, fuel pump, injectors, pressure regulator, and troubleshooting.

Ignition System:

Electronic ignition system, ignition coils, spark plugs, and diagnostic procedures.

Transmission System:

5-speed constant mesh gearbox, clutch assembly, primary drive, troubleshooting, and repair.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator), starting system (starter motor, solenoid), lighting, instrumentation, and accessories.

Braking System:

Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.

Suspension System:

Front fork (telescopic), rear shock absorbers, swingarm, troubleshooting, and adjustment.

Steering System:

Handlebars, triple clamps, steering head bearings, and troubleshooting.

Frame And Bodywork:

Frame inspection, mounting points, body panels, fenders, fuel tank, seat, and associated hardware.

Procedures Included

Scheduled Maintenance:

Detailed procedures for all routine maintenance tasks including oil changes, filter replacements, chain adjustments, and lubrication.

Engine Repair:

Complete engine rebuild procedures, piston replacement, valve adjustments, cylinder head service, and gasket replacement.

Transmission Repair:

Gearbox disassembly and reassembly, clutch service, and troubleshooting of shifting issues.

Electrical Diagnostics:

Step-by-step diagnostic routines for electrical faults, including use of multimeters and wiring diagrams.

Brake Service:

Detailed instructions for brake pad replacement, caliper service, master cylinder overhaul, and brake line maintenance.

Suspension Overhaul:

Front fork seal replacement, rear shock absorber replacement, and steering head bearing service.

Fuel System Diagnosis:

Troubleshooting of fuel delivery issues, sensor diagnostics (e.g., TPS, MAP), and idle speed adjustment.

Troubleshooting Guides:

Extensive troubleshooting sections covering common problems with symptoms and suggested solutions for all major systems.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance and fluid checks to complete engine and transmission overhauls, electrical system diagnostics, and chassis component repairs.

Diagnostic Procedures:

Detailed diagnostic flowcharts and procedures for identifying and resolving mechanical and electrical issues.

Special Tool Requirements:

Lists and descriptions of special tools required for specific repair procedures, often including Harley-Davidson OEM tool numbers.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, searchable text with clear diagrams and illustrations suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

3.496 in. x 3.811 in. (88.8 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valvetrain:

OHV, 2 valves per cylinder, pushrod actuated

Carburetion Injection:

Electronic Sequential Port Fuel Injection (ESPFI)

Performance

Horsepower:

Approximately 65-70 HP (est. at crank, varies by model and tuning)

Torque:

Approximately 70-75 ft-lbs @ 3500 RPM (est. at crank, varies by model)

Fuel System

Fuel Type:

Unleaded gasoline, minimum 91 octane (AKI)

Fuel Tank Capacity:

3.1 gallons (11.7 L) or 4.5 gallons (17.0 L) depending on model variant (e.g., XL1200C)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh

Primary Drive:

Duplex chain, 1.400:1 ratio

Final Drive:

Belt drive, 3.15:1 ratio

Features

Clutch Type:

Wet, multi-plate

Transmission Fluid Spec:

Harley-Davidson Transmission Fluid (or equivalent SAE 80W-90 API GL-5) - Capacity: 24 fl oz (710 ml)

📐 Dimensions

Exterior

Length:

Approx. 88.0 in. (2235 mm) (Varies by model)

Width:

Approx. 35.5 in. (901 mm) (Handlebar width, varies by model)

Height:

Approx. 48.5 in. (1232 mm) (Seat height unloaded, varies by model)

Weights

Dry Weight:

Approx. 545 lbs (247 kg) to 555 lbs (252 kg) (Varies by model)

Gross Vehicle Weight Rating Gvwr:

Approx. 900 lbs (408 kg)

Payload Capacity:

Approx. 350 lbs (159 kg)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not typically subjected to standardized crash test ratings like passenger cars. Safety depends heavily on rider skill and adherence to safe riding practices.

Active Features

Braking System Type:

Hydraulic disc brakes front and rear.

ABS Availability:

ABS was an optional feature on some 2009 Sportster models, not standard across the board.

Passive Features

Lighting System:

Halogen headlight, LED taillight, front and rear turn signals.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation (speedometer, tachometer on some models, odometer, trip meter, fuel gauge, indicator lights). No integrated infotainment system as found on modern touring bikes.

Driver Assistance

Driver Assistance Features:

None. Focus is on core motorcycle mechanics and rider control.

Connectivity

Connectivity Features:

None. Primarily mechanical and electrical systems. Accessories like security systems or aftermarket Bluetooth devices could be added.

🔧 Maintenance

Service Intervals

First Service Mileage:

1,000 miles (1,600 km)

Subsequent Service Interval:

Every 5,000 miles (8,000 km)

Oil Change Interval:

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

Transmission Fluid Change Interval:

Every 10,000 miles (16,000 km)

Primary Chain Case Fluid Change Interval:

Every 10,000 miles (16,000 km)

Fluid Specifications

Engine Oil Spec:

Harley-Davidson 20W-50 SYN3 (or equivalent SAE 20W-50 API SG or higher)

Engine Oil Capacity:

3.0 US qt (2.8 L) (with filter change)

Primary Chain Case Oil Spec:

Harley-Davidson Primary Chain Lubricant (or equivalent SAE 80W-90 API GL-4)

Primary Chain Case Oil Capacity:

28 US fl oz (828 ml)

Brake Fluid Spec:

DOT 4

Known Issues

Ignition Module Failures:

Early models of the Evolution engine could experience ignition module failures, though often addressed by this era.

Carburetor Issues:

While this model is fuel-injected, earlier carburetors could have tuning issues; EFI systems can have sensor or injector problems.

Charging System Reliability:

Stator or regulator failures can occur over time, impacting battery charging.

📚 Vehicle History

Brand Heritage

Harley Davidson Founding:

Founded in 1903 in Milwaukee, Wisconsin, Harley-Davidson is an iconic American motorcycle manufacturer with a rich heritage in performance and customization.

Model Evolution

Sportster Introduction:

The Sportster line was first introduced in 1957, evolving significantly over decades from its ironhead engine origins to the Evolution engine platform.

Evolution Engine Introduction:

The Evolution engine, often referred to as the 'Blockhead', was introduced in 1984 for Big Twin models and later adapted for Sportsters.

Production

Manufacturing Location:

🏆 Awards & Recognition

Recognitions

Harley Davidson Brand Recognition:

Consistently recognized as a leading American motorcycle brand with a strong cultural following and reputation for durability and classic style.

Ratings

Sportster Model Ratings 2009:

Generally well-regarded by enthusiasts for its performance, handling, and customization potential within the cruiser segment.

Certifications

Manual Certification:

Professional workshop quality, reflecting standard industry practices for repair and maintenance documentation.