Market Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Owners, Independent Repair Shops, DIY Enthusiasts
Manual Advantage:
Provides Official Factory Data, Superior to Generic Aftermarket Guides
Key Benefit:
Enables Comprehensive DIY Maintenance and Repair for the XL1200R
Documentation Type:
Factory Service Manual
Engine:
Complete Engine Assembly, Internal Components, Ignition, Fuel System, Lubrication, Cooling (Air)
Transmission:
Gearbox Assembly, Clutch, Shifting Mechanism, Final Drive
Electrical:
Wiring Diagrams, Lighting, Ignition System, Charging System, Starter, Instrumentation, Sensors, ECM/ECU
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Exhaust System
Bodywork:
Body Panels, Fenders, Fuel Tank, Seat, Handlebars, Controls, Fairings (if applicable)
Maintenance:
Routine Service, Scheduled Maintenance, Lubrication Points, Fluid Changes, Filter Replacements
Troubleshooting:
Diagnostic Procedures, Symptom-Based Troubleshooting, Fault Code Interpretation
Repair:
Component Disassembly, Reassembly, Adjustment, Calibration, Replacement
Overhaul:
Engine Rebuild, Transmission Overhaul, Component Restoration
Specifications:
Torque Values, Clearances, Tolerances, Electrical Specifications
Depth:
Comprehensive Factory Level Detail
Diagnostic Capability:
Advanced Diagnostic Procedures for All Major Systems
Rebuild Instructions:
Detailed Step-by-Step Rebuild Procedures for Engine, Transmission, and Major Components
Engine Type:
Evolution V-Twin (Air-Cooled)
Displacement:
73.4 cu in (1202 cc)
Bore X Stroke:
3.500 in x 3.812 in (88.9 mm x 96.8 mm)
Horsepower Estimated:
Approx. 65-70 HP (Varies with exhaust/tuning)
Torque Estimated:
Approx. 70-75 lb-ft @ 3500 RPM (Varies with exhaust/tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, Minimum 91 Octane (AKI)
Ignition System:
Electronic Ignition with Knock Control
Oil Type:
Harley-Davidson Syn3 (or equivalent SAE 20W50 motorcycle oil)
Oil Capacity W Filter:
3.0 US qt (2.8 L)
Crash Test Ratings:
N/A (Motorcycle, Not Applicable)
Braking System:
Dual Disc Front Brakes, Single Disc Rear Brake
ABS:
Optional (Check Specific Build)
Lighting:
Halogen Headlight, LED Tail/Stop Light, Amber Turn Signals
Infotainment System:
Basic Instrumentation (Speedometer, Tachometer, Odometer, Trip Meter, Fuel Gauge)
Audio System:
N/A (Typically aftermarket upgrade)
Cruise Control:
N/A (Not factory standard on this model)
Connectivity Features:
N/A
ECM:
ECM (Electronic Control Module) controlling fuel injection and ignition timing
First Service:
1,000 miles (1600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter
Primary Fluid:
Harley-Davidson Primary Fluid (or equivalent SAE 85W-140)
Common Wear Items:
Clutch plates, primary chain tensioner, voltage regulator, wheel bearings, spark plugs
Potential Faults 2010:
Some early models might exhibit issues with the automatic compression releases (ACRs) on the starter system, though typically addressed via software updates or component replacement. Check for potential exhaust gasket leaks.
Oil Filter Part Number:
Typically 63796-77A or 63731-98 (Verify with VIN)
