Harley Davidson XL1200C 2009 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Year: 2009 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Vehicle Segment: Cruiser Motorcycle Target Audience: Enthusiasts, owners, and professional...

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类型: Motorcycle

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标签: 2009 Harley Davidson Misc Motorcycle Motorcycles XL1200C

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XL1200C

Year:

Product Type:

Service Repair Workshop Manual

👋 Introduction

Market Position

Vehicle Segment:

Cruiser Motorcycle

Target Audience:

Enthusiasts, owners, and professional mechanics working on Harley-Davidson XL1200C models.

Competitive Analysis

Competitors:

Other cruiser motorcycles of similar displacement from brands like Indian, Victory, and some Japanese manufacturers.

Key Features

Vehicle Appeal:

Iconic styling, V-twin engine character, customization potential, strong brand loyalty.

Manual Value Proposition:

Provides essential, factory-authorized information for maintaining and repairing the specific model, ensuring longevity and performance.

📋 Manual Details

Coverage Areas

Engine Service:

Complete

Transmission Service:

Complete

Chassis Service:

Complete

Electrical System:

Complete

Fuel System:

Complete

Brake System:

Complete

Suspension System:

Complete

Bodywork And Frame:

Complete

Troubleshooting:

Comprehensive Diagnostic Procedures

Page Count

Estimated Pages:

Approximately 500-700 (typical for this model/type)

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, though physical may exist)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, assembly, inspection, repair of cylinders, pistons, crankshaft, camshafts, valves, and timing.

Fuel And Ignition:

Carburetor (if applicable for the specific model variant, though 2009 XL1200C likely has fuel injection) or EFI system, fuel pump, injectors, ignition system, spark plugs, ignition timing.

Exhaust System:

Mufflers, pipes, catalytic converter (if equipped), and mounting.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly and assembly, primary drive, final drive (belt drive).

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, ignition switch, security system.

Brake System:

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

Suspension And Steering:

Front fork (telescopic) overhaul, rear shock absorber replacement, steering head bearings.

Wheels And Tires:

Wheel bearing replacement, tire mounting and balancing, spoke wheel maintenance (if applicable).

Frame And Bodywork:

Frame inspection, fuel tank removal and installation, fenders, seat, handlebars, controls.

Procedures Included

Maintenance:

Routine checks, lubrication, filter replacement, fluid changes, spark plug replacement, belt tension adjustment.

Diagnostics:

Troubleshooting charts for common problems, fault code retrieval (if applicable to EFI), component testing.

Repair:

Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.

Overhaul:

Complete engine, transmission, and fork overhauls.

Adjustments:

Clutch adjustment, throttle cable adjustment, brake lever adjustment.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine rebuilds and electrical system diagnostics.

Detail Level:

Includes detailed diagrams, exploded views, torque specifications, and diagnostic flowcharts.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - assumed for digital versions. Enables searchability and easy navigation.

Print Quality

Quality:

High resolution scans or original digital files, ensuring clarity of text and diagrams.

Binding Type

Binding:

N/A (for digital); Professional perfect binding or lay-flat spiral binding (for physical reprints).

Paper Type

Paper:

N/A (for digital); High-quality, durable paper stock suitable for workshop environments (for physical reprints).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Valve Train:

Overhead Valves (OHV) with pushrods, 2 valves per cylinder

Performance

Horsepower:

Approximately 65-70 HP (estimated, actual figures vary)

Torque:

Approximately 70-75 lb-ft (estimated, actual figures vary)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) - Standard for 2009 XL1200C

Fuel Type:

Unleaded gasoline, minimum 91 octane (RM)

Cooling System

Type:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed, Cruise Drive

Primary Drive:

Chain, 34/46 ratio

Final Drive:

Belt, 29/68 ratio

Features

Clutch Type:

Wet, multi-plate

Transmission Fluid Type:

Harley-Davidson SYN3 (or equivalent motorcycle specific transmission oil)

📐 Dimensions

Exterior

Length:

90.4 in (2296 mm)

Seat Height Laden:

26.3 in (668 mm)

Ground Clearance:

4.3 in (109 mm)

Weights

Dry Weight:

573 lb (260 kg)

Gross Vehicle Weight Rating:

939 lb (426 kg)

Fuel Capacity:

4.5 gal (17.0 L)

🛡️ Safety Features

Ratings

Crash Safety:

Motorcycles are not typically subject to standardized crash ratings like automobiles. Safety relies on design, rider skill, and protective gear.

Active Features

Brakes:

Dual-action, front and rear disc brakes.

Lighting:

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

Passive Features

Frame Construction:

Steel frame and swingarm construction.

Ergonomics:

Designed for rider comfort and control, with forward-mounted controls and a low seat height.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer, fuel gauge, indicator lights. Often includes a trip odometer and clock.

Audio System:

Not typically standard on this model. Aftermarket audio systems are common.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature on many Harley-Davidson models, including the XL1200C for this year. Availability would depend on the specific bike's configuration.

Connectivity

Security System:

Factory-installed H-D Smart Security System with proximity-based fob is often standard or optional.

🔧 Maintenance

Service Intervals

Initial Service:

Approximately 1,000 miles (1,600 km) - typically includes oil change, primary chain adjustment, inspection.

Subsequent Service:

Every 5,000 miles (8,000 km) or annually - includes engine oil and filter change, check belt tension, inspect brakes, chassis lubrication, etc.

Major Service Intervals:

Refer to manual for specific intervals for valve adjustments, spark plug replacement, and other major component checks.

Fluid Specifications

Engine Oil:

Harley-Davidson SYN3 (20W-50) or equivalent motorcycle-specific oil meeting HD-2 specification.

Primary Chain Case Fluid:

Harley-Davidson SYN3 (20W-50) or HD-1 specification motorcycle oil.

Transmission Fluid:

Harley-Davidson SYN3 (20W-50) or equivalent motorcycle specific transmission oil.

Brake Fluid:

DOT 4.

Known Issues

Common Wear Items:

Clutch plates, brake pads, tires, drive belt, fork seals, wheel bearings.

Potential Issues:

EFI sensor issues (e.g., Throttle Position Sensor, Manifold Absolute Pressure Sensor), voltage regulator failure, early model transmission seal leaks (though less common by 2009).

📚 Vehicle History

Brand Heritage

Brand History:

Harley-Davidson is an iconic American motorcycle manufacturer with a history dating back to 1903, renowned for its V-twin engines and cruiser styling.

Model Evolution

Sportster Lineage:

The XL series, or 'Sportster', is one of Harley-Davidson's longest-running model lines, evolving from a sporty, lightweight machine to a more substantial cruiser.

Xl1200C Evolution:

The XL1200C Custom model, introduced in the mid-1990s, focused on classic styling cues like chrome, spoked wheels, and a lower seat height, becoming a popular configuration.

Production

Manufacturing Location:

United States (primarily Kansas City, Missouri and York, Pennsylvania)

Key Updates 2009:

The 2009 model year saw updates including potentially revised styling, improved EFI calibration, and possibly minor chassis or suspension tweaks. The manual would reflect these specific changes.

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Harley-Davidson Sportster line, including the XL1200C, is consistently recognized for its styling, performance, and customization potential, often appearing on 'best cruiser' lists.

Certifications

Compliance:

Meets all applicable US EPA and California Air Resources Board (CARB) emissions standards for its model year.