Category:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle enthusiasts.
Segment:
Mid-weight cruiser segment, competing with models from Indian Motorcycle, Yamaha, Honda.
Styling:
Classic cruiser aesthetics, ample chrome, comfortable riding position, custom-oriented design.
Engine Emphasis:
Torque-rich V-twin engine, renowned for its distinctive rumble and low-end power.
Engine:
Complete engine assembly, disassembly, tuning, ignition system, lubrication system, cooling system (air).
Transmission:
Gearbox overhaul, clutch operation, primary drive, final drive belt inspection and adjustment.
Chassis:
Frame inspection and repair, front fork service, rear suspension adjustment and replacement, wheel bearings, steering head bearings.
Electrical:
Wiring diagrams, lighting system, ignition system, starting system, charging system, battery maintenance, electronic diagnostic codes.
Brakes:
Brake system inspection, hydraulic service, pad replacement, caliper overhaul, rotor inspection.
Fuel System:
Carburetor (Keihin CV) disassembly, cleaning, adjustment, fuel tank and lines, fuel filter replacement.
Bodywork:
Fender removal/installation, fuel tank mounting, seat assembly, handle bar components, exhaust system.
Maintenance:
Oil changes, filter replacements, spark plug service, drive belt adjustment, chain lubrication and adjustment (if applicable), brake fluid flush, tire pressure checks, battery charging.
Troubleshooting:
Diagnostic charts for common problems, identification of symptoms and causes, repair procedures for electrical and mechanical faults.
Repair:
Detailed step-by-step instructions for component removal, rebuilding, and reinstallation across all major systems.
Overhaul:
Comprehensive guides for complete engine, transmission, and suspension component rebuilds.
Depth:
Advanced diagnostics, complete engine rebuilds, electrical system troubleshooting, suspension tuning, carburetor calibration, comprehensive torque specifications.
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.496 in. x 3.800 in. (88.8 mm x 96.5 mm)
Valve Train:
Overhead valves (OHV), two valves per cylinder, pushrod actuated.
Horsepower Approx:
Approx. 60-65 HP (at crankshaft, depending on tuning)
Torque Approx:
Approx. 67-70 ft-lbs (at crankshaft, depending on tuning)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Type:
Dry sump lubrication system
Oil Capacity:
3.0 US qt (2.8 L)
Oil Filter Part Number:
Harley-Davidson OEM 63796-77A (or equivalent aftermarket)
Recommended Spark Plug:
Harley-Davidson OEM 32305-99 (or equivalent NGK, Champion)
Type:
5-speed constant mesh, helical gears
Primary Drive:
Chain, 34/46 tooth
Final Drive:
Belt drive, 32/66 tooth (32T front, 66T rear)
Clutch Type:
Wet, multi-plate
Transmission Oil Type:
Harley-Davidson Syn-3 or HD Formula+ (or equivalent SAE 50W motorcycle oil)
Transmission Oil Capacity
Capacity:
2.8 US qt (2.6 L)
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized in the same way as automobiles)
Brakes:
Hydraulic disc brakes front and rear
Lighting:
Halogen headlight, taillight, turn signals
Frame Construction:
Steel frame for structural integrity
Ride Control:
Stability derived from rider input and chassis design
Audio System:
None (Stock 2002 model typically lacks integrated infotainment)
ABS:
Not available on standard 2002 XL1200C models
Bluetooth Usb:
Not available (Aftermarket options exist)
Dashboard:
Analog speedometer with integrated tachometer, odometer, trip meter, neutral indicator, oil pressure light, turn signal indicators, low fuel warning light.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months thereafter.
Engine Oil Change:
Every 2,500 miles (4,000 km) or 6 months, whichever comes first, for Harley-Davidson branded oil. Refer to manual for extended intervals with Syn-3.
Engine Oil Type:
Harley-Davidson Syn-3 (Fully Synthetic) or Harley-Davidson 20W-50 motorcycle oil. Refer to manual for specific viscosity recommendations based on temperature range.
Primary Chain Case Oil Type:
Harley-Davidson Formula+ (or equivalent SAE 50W motorcycle oil)
Brake Fluid Type:
DOT 4 hydraulic fluid
Fork Oil Type:
Refer to manual for specific viscosity (typically 10W or 15W fork oil)
Common Complaints:
Carburetor tuning sensitivity, starter solenoid issues, rear brake fade on extended use, primary drive chain adjustment frequency.
Potential Upgrades:
Aftermarket ignition modules, performance exhaust systems, carburetor jet kits for improved performance and throttle response.
Brand Identity:
Iconic American motorcycle manufacturer known for its V-twin engines and cruiser lifestyle.
Sportster Introduction:
The Sportster line was first introduced in 1957, evolving into a core platform for Harley-Davidson.
Xl1200C Introduction:
The XL1200C Custom variant became popular for its factory custom styling, building on the Sportster platform.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri)
