Segment:
Cruiser / Custom Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, DIY enthusiasts
Competitors:
Similar models from Indian, Victory, and custom-built motorcycles
Vehicle Appeal:
Classic Harley-Davidson styling, strong V-twin performance, customizability
Manual Value Proposition:
Enables owners and technicians to maintain, diagnose, and repair their XL1200C to factory standards, saving time and money.
Primary Coverage:
Complete Service, Repair, and Workshop Procedures
Secondary Coverage:
Troubleshooting, Diagnostics, Maintenance, Electrical Diagrams, Component Removal/Installation
Estimated Pages:
800-1000 (typical for full factory service manuals)
Type:
Factory Service Manual / Workshop Manual
Engine:
Engine Assembly, Disassembly, Top End, Bottom End, Lubrication System, Fuel System (EFI), Ignition System, Cooling System (Air-Cooled)
Transmission:
Transmission Assembly, Disassembly, Clutch, Drive System (Belt Drive)
Electrical:
Wiring Diagrams, Lighting, Ignition System, Starting System, Charging System, Battery, Gauges, Controls, ECM
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Steering, Wheels, Tires, Brakes (Front and Rear Disc), Swingarm
Bodywork:
Body Panels, Fenders, Fuel Tank, Seat, Handlebars, Controls, Exhaust System
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Service, Brake Fluid Flush, Belt Tension Adjustment
Repair:
Engine Rebuilds, Transmission Overhaul, Suspension Overhauls, Brake System Repairs, Electrical Component Replacement
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting
Installation:
Component Installation and Removal, Accessory Installation Guidelines
Depth:
Comprehensive, from basic inspections to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.
Engine Type:
Air-Cooled, Evolution V-Twin
Displacement:
1200 cc (73.3 cubic inches)
Bore X Stroke:
3.500 in x 3.813 in (88.9 mm x 96.8 mm)
Valve Train:
Overhead Valve (OHV), 2 valves per cylinder
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Horsepower Estimated:
Approx. 65-70 HP @ 5200 RPM (Note: Harley-Davidson often doesn't publish official HP figures)
Torque Estimated:
Approx. 79 ft-lbs @ 3500 RPM
Fuel Type:
Unleaded Gasoline, Minimum 91 Octane
Fuel Tank Capacity:
3.3 US gal (12.5 L)
Type:
5-Speed Cruise Drive
Final Drive:
Carbon fiber belt, 32/66 ratio
Clutch Type:
Clutched, multi-plate, wet
Transmission Fluid Type:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant or equivalent (e.g., SAE 50Wt motorcycle specific)
Primary Chaincase Capacity:
2.7 US qt (2.5 L)
Crash Test Ratings:
Motorcycles are not typically subjected to formal crash testing like passenger cars. Safety relies on rider skill and adherence to operational guidelines.
Braking System:
Dual-piston front and rear disc brakes with solid brake rotors
Lighting:
Halogen headlamp, LED tail lamp, amber front and rear turn signals
Frame Construction:
Steel frame and swingarm for rigidity
Tires:
Tubeless tires (Front: MH90-21, Rear: 150/80B16)
Instrumentation:
Analog speedometer, tachometer, fuel gauge, and indicator lights
Features:
Classic styling, basic rider information display
ABS:
Not standard on 2009 XL1200C model (optional availability should be verified)
Bluetooth Audio:
No integrated Bluetooth audio or smartphone connectivity.
Oil Change Interval:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Primary Chaincase Oil Change:
Every 10,000 miles (16,000 km)
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Drive Belt Tension Check:
Every 5,000 miles (8,000 km)
Engine Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil SAE 20W-50 or H-D 360 Motorcycle Oil SAE 20W-50 (Check manual for exact spec and capacity)
Engine Oil Capacity:
Approx. 3.0 US qt (2.8 L) with filter change
Common Wear Items:
Clutch plates, drive belt, wheel bearings, brake pads, fork seals
Electrical Potential Issues:
Wiring harness connectors, regulator/stator failures (common across many Harley models of this era)
Brand Origin:
Founded in 1903 in Milwaukee, Wisconsin, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Sportster Lineage:
The Sportster line dates back to the late 1950s, evolving from the Ironhead to the Evolution engine. The XL1200C Custom is a modern interpretation focusing on classic cruiser aesthetics and a larger displacement engine.
Manufacturing Location:
United States (typically Milwaukee, Wisconsin or Kansas City, Missouri for this era)
Model Positioning 2009:
The 2009 XL1200C was a popular model within the Harley-Davidson lineup, offering a balance of classic styling, manageable size, and the legendary V-twin performance at a more accessible price point compared to larger touring models.
