Harley Davidson XR1200 2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XR1200 Year: 2010 👋 Introduction Market Position Positioning: The Harley-Davidson XR1200 was positioned as a performance-oriented sport motorcycle, diverging from Harley's traditional cruiser...

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类型: Motorcycle

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标签: 2010 Harley Davidson Motorcycle Motorcycles Sportster XR1200

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XR1200

Year:

👋 Introduction

Market Position

Positioning:

The Harley-Davidson XR1200 was positioned as a performance-oriented sport motorcycle, diverging from Harley's traditional cruiser image. It was designed to appeal to a broader, more performance-focused rider demographic.

Competitive Analysis

Competitors:

Competed in a segment with other performance street bikes, including models from European manufacturers like Ducati and Triumph, as well as Japanese sportbikes.

Key Features

Features:

Sport-tuned suspension, powerful V-twin engine, performance-oriented chassis, dual front disc brakes, distinctive XR styling inspired by Harley's racing heritage.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Page Count:

Language:

English

Format:

Accessibility:

Instant Download

📖 Manual Coverage

Systems Covered

Systems:

Engine, Fuel System, Ignition System, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Lighting, Bodywork, Frame, Controls, Wheels, Tires, Maintenance, Troubleshooting, Diagnostics, Special Tools

Procedures Included

Procedures:

Removal, Installation, Disassembly, Assembly, Adjustment, Inspection, Repair, Maintenance, Troubleshooting, Diagnostic Procedures, Wiring Diagrams, Torque Specifications, Wear Limits, Fluid Specifications, Service Data

Technical Depth

Depth:

Comprehensive: From basic maintenance and adjustments to complete engine rebuilds, electrical system diagnostics, and frame repairs. Detailed step-by-step instructions with pictorial diagrams.

📊 Manual Specifications

File Specifications

File Format:

Print Quality:

Printable (all pages)

Readability Requirement:

Adobe Reader

Operating System Compatibility:

Windows, Mac, Linux OS

Manual Type Details

Manual Purpose:

Repair and Maintenance

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution® Sportster® V-twin

Displacement:

1200cc (73.2 cu in)

Bore X Stroke:

3.5 in x 3.8125 in (88.9 mm x 96.8 mm)

Compression Ratio:

10.0:1

Performance

Horsepower:

Approx. 92 hp @ 7000 rpm (specifications may vary slightly by region)

Torque:

Approx. 79 ft-lbs (107 Nm) @ 6000 rpm (specifications may vary slightly by region)

Fuel System

Fuel Delivery:

Fuel Injection (Electronic Sequential Port Fuel Injection - ESPFI)

Ignition System:

High-performance ignition module

Cooling System

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Clutch Type:

Clutch cable-operated, wet, multi-plate

Features

Final Drive:

Belt Drive

📐 Dimensions

Exterior

Length:

Approx. 85.1 in (2162 mm)

Width:

Approx. 32.5 in (825.5 mm)

Height:

Approx. 46.8 in (1188.7 mm)

Weights

Dry Weight:

Approx. 478 lbs (217 kg)

Gvwr:

Approx. 880 lbs (400 kg)

Weight Distribution:

Designed for balanced handling, emphasizing mass centralization for performance.

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with relevant national and international motorcycle safety standards. The manual emphasizes safe operating procedures and the use of appropriate safety gear.

Active Features

Braking System:

Dual 320mm floating discs with 4-piston calipers (front), Single 260mm disc with 2-piston caliper (rear). ABS was an optional feature on some markets.

Suspension Stability:

Upside-down cartridge forks (front) and adjustable rear shock absorbers contribute to stability and control.

Passive Features

Frame Construction:

Steel trellis frame designed for rigidity and precise handling.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer and speedometer, digital odometer, trip meter, clock, fuel level indicator, and indicator lights. The manual details the function and troubleshooting of the instrument cluster.

Driver Assistance

ABS Option:

Anti-lock Braking System (ABS) was an optional feature on some XR1200 models, requiring specific diagnostic and repair procedures covered in the manual.

Connectivity

Diagnostic Ports:

Diagnostic ports are present, and the manual likely references diagnostic codes and procedures for use with Harley-Davidson diagnostic equipment.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 miles (8,000 km) or annually. The manual will specify exact intervals and procedures.

Fluid Specifications

Engine Oil Type:

Harley-Davidson recommended V-Twin synthetic oil (e.g., SYN3) or equivalent meeting specifications outlined in the manual. Viscosity typically 20W-50.

Transmission Fluid Type:

Harley-Davidson transmission fluid or equivalent meeting specified standards.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Tires, brake pads, clutch plates, drive belt, spark plugs, air filter. The manual details inspection and replacement procedures.

Potential Concerns:

Some owners have reported occasional issues with regulator/rectifier components or minor electrical gremlins, which this manual will help diagnose and repair.

Maintenance Chart

Chart Availability:

The manual includes a periodic maintenance chart with recommended service schedules and checks.

Tool Requirements

Special Tools:

The manual references specific Harley-Davidson special service tools required for certain procedures, ensuring correct and safe repair.

📚 Vehicle History

Brand Heritage

Heritage Connection:

The XR designation is a nod to Harley-Davidson's XR750 flat-track racing motorcycle, bringing a performance and racing pedigree to the street model.

Model Evolution

Development:

Developed in collaboration with Race Tech, the XR1200 was Harley-Davidson's attempt to create a more performance-oriented motorcycle for global markets, particularly Europe.

Production

Production Years:

2008-2013 (XR1200), 2009-2012 (XR1200X - higher spec model)

Manufacturing Location:

Kansas City, Missouri, USA

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

While specific awards are not as widely documented as for some mainstream motorcycles, the XR1200 was generally praised by critics for its sporting intentions and departure from convention for Harley-Davidson.