Positioning:
The Harley-Davidson XL1200C (Sportster Custom) is a quintessential cruiser motorcycle, known for its classic styling and accessible performance. This manual targets owners and technicians who want to maintain and repair this iconic model.
Competitors Historical:
Competes with other mid-size American and Japanese cruisers, offering a blend of heritage and modern technology.
Model Focus:
Emphasis on customization, comfortable riding position, and the distinctive Harley-Davidson V-twin experience.
Purpose:
Provides the in-depth technical knowledge required for all service, maintenance, and repair tasks, empowering owners to take control of their motorcycle's upkeep.
Engine:
Complete engine overhaul, diagnostics, tuning, component specifications
Transmission:
Gearbox service, clutch, primary drive, final drive maintenance
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body diagnostics
Electrical System:
Wiring diagrams, ignition system, charging system, lighting, instrumentation, starter
Braking System:
Front and rear brake service, hydraulic system, bleeding procedures
Suspension:
Front fork service, rear shock absorber replacement and adjustment
Chassis And Frame:
Frame inspection, steering head bearing service, wheel and tire maintenance
Bodywork And Trim:
Body panel removal and installation, fenders, fuel tank, seat
Exhaust System:
Exhaust pipe and muffler inspection and replacement
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, battery care
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation
Repair:
Step-by-step repair instructions for all major components and systems
Overhaul:
Complete engine and transmission rebuild procedures
Diagnostics:
Detailed diagnostic trees and procedures for electrical and mechanical faults
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
Engine Type:
Evolution V-Twin, Air-Cooled
Displacement:
1200cc (1199.8 cc)
Bore X Stroke:
3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)
Horsepower Estimated:
Approximately 65-70 HP (at crankshaft, actual may vary)
Torque Estimated:
Approximately 70-75 lb-ft (at crankshaft, actual may vary)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI
Length:
Approx. 90.3 in. (2295 mm)
Width:
Approx. 36.5 in. (927 mm)
Height:
Approx. 48.6 in. (1234 mm)
Wheelbase:
Approx. 60.0 in. (1524 mm)
Ground Clearance:
Approx. 4.8 in. (122 mm)
Dry Weight:
Approx. 560 lbs (254 kg)
Gross Vehicle Weight Rating:
Approx. 930 lbs (422 kg)
Fuel Capacity:
5.0 gal (18.9 L)
Crash Test Ratings:
N/A (Motorcycle specific safety is addressed through design and components)
Braking:
Dual disc front brakes, single disc rear brake with optional ABS (Anti-lock Braking System) available on some configurations.
Lighting:
Halogen headlight, LED tail/stop light, amber front and rear turn signals.
Frame Construction:
Steel frame and swingarm designed for stability and rider control.
Tires:
Tubeless, radial tires for improved handling and puncture resistance.
Instrumentation:
Analog speedometer with integrated tachometer, fuel gauge, gear indicator, and indicator lamps.
Audio System:
N/A (This model does not typically come with a factory-installed audio system, focusing on the riding experience).
ABS:
Optional Anti-lock Braking System (ABS) available on some configurations for enhanced braking control.
Diagnostic Port:
Access to diagnostic information via a data link connector, allowing for engine management system (ECM) diagnostics and tuning.
Oil Change Interval:
Typically every 2,500-5,000 miles or annually, refer to manual for exact schedule.
Primary Chain Tensioner Inspection:
Regular inspection recommended, particularly for earlier models with hydraulic tensioners.
Spark Plug Replacement:
Typically every 10,000-20,000 miles.
Engine Oil Type:
Harley-Davidson Genuine V-Twin Oil SAE 20W50 or equivalent API SG, JASO FD approved.
Engine Oil Capacity:
3.0 US qt. (2.8 L) with filter change.
Primary Chain Case Oil Type:
Harley-Davidson Genuine Primary Chain Case Lubricant or equivalent.
Primary Chain Case Oil Capacity:
2.8 US qt. (2.6 L).
Transmission Oil Type:
Harley-Davidson Genuine Formula + Transmission & Primary Chain Case Lubricant or equivalent.
Transmission Oil Capacity:
1.0 US qt. (0.95 L).
Brake Fluid Type:
DOT 4 High Performance Synthetic Brake Fluid.
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, wheel bearings.
Potential Faults:
Primary chain tensioner wear (especially on earlier models with non-hydraulic tensioners), fuel injector issues, speedometer drive gear wear (on earlier models with speedometers driven by the transmission).
Brand Legacy:
Harley-Davidson, founded in 1903, is an American icon synonymous with cruiser motorcycles and a distinct riding culture.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model family. The XL1200C Custom variant emphasizes classic styling cues and customization potential.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin or York, Pennsylvania)
Model Introduction Year:
The XL1200C designation has been in use for many years, evolving through various iterations of the Sportster platform.
Model Achievements:
The Sportster line, including the XL1200C, is consistently recognized for its iconic styling, customization potential, and contribution to motorcycling culture. Specific awards for the 2010 model are not prominently documented, but its enduring popularity speaks to its success.
Reliability Perception:
Harley-Davidson Sportsters are generally perceived as reliable and durable, with ongoing maintenance contributing significantly to longevity.
