🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2010

Product Type:

Workshop Service Repair Manual

👋 Introduction

Market Segment:

Cruiser motorcycle, popular for custom styling and accessible performance.

Key Competitors 2010:

Similar displacement cruisers from brands like Indian, Triumph, and potentially some Japanese manufacturers in the cruiser segment.

Xl1200C Defining Characteristics:

Chrome-rich styling, lower seat height, forward foot controls, classic Harley-Davidson V-twin engine character, rider comfort for cruising.

Manual Utility:

Essential resource for owners and technicians seeking accurate, factory-level repair and maintenance information to keep the XL1200C in optimal condition.

📋 Manual Details

Coverage Scope:

Complete official factory service repair manual

Page Count Estimated:

Hundreds of pages (specific count not provided in description, but implies comprehensive)

Manual Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Service:

Engine disassembly, assembly, inspection, troubleshooting, performance tuning

Fuel System Service:

Fuel injection system (EFI), fuel pump, fuel filter, fuel tank, fuel lines

Ignition System Service:

Ignition module, spark plugs, ignition coils, wiring

Transmission Service:

Clutch, gearbox, primary drive, final drive, lubrication

Electrical System Service:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, wiring diagrams

Chassis Service:

Frame, front suspension (forks), rear suspension (shocks), steering system

Brake System Service:

Front and rear brakes, brake lines, calipers, master cylinders, fluid bleeding

Wheel And Tire Service:

Wheel bearing replacement, tire mounting and balancing, spoke adjustment (if applicable)

Exhaust System Service:

Exhaust pipes, mufflers, mounting hardware

Bodywork And Trim Service:

Fenders, fuel tank, seat, handlebars, mirrors, decorative trim

Maintenance Procedures:

Regular scheduled maintenance, fluid changes, filter replacements, lubrication, adjustments

Troubleshooting Guides:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting

Repair Procedures:

Detailed step-by-step instructions for component removal, repair, and reinstallation

Rebuild Procedures:

Complete engine and transmission rebuild guidelines

Special Tool Requirements:

Identification of necessary special tools for specific repair tasks

Torque Specifications:

Precise torque values for critical fasteners

Technical Depth:

Comprehensive, covering from basic routine maintenance to complete engine and transmission overhauls, including electrical diagnostics and chassis adjustments.

📊 Manual Specifications

File Format:

PDF

Print Quality Implication:

Designed for high-quality printing, allowing for clear reproduction of diagrams and text.

Binding Type For Print:

Printable in its entirety, suitable for binding (e.g., spiral, comb, three-ring).

Paper Type For Print:

Standard paper; manual can be printed on durable stock for workshop use.

Searchable Text:

Implied by PDF format, allowing for keyword searching of technical information.

Manual Completeness:

Indicated as 'COMPLETE official full factory service repair manual', signifying all aspects of repair and maintenance.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Engine Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.500 in x 3.812 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.7:1

Horsepower Estimated:

Approximately 65-70 HP (at crankshaft, model specific)

Torque Peak Estimated:

Around 70-75 ft-lbs (at crankshaft, model specific)

Fuel System Type:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type Required:

Unleaded gasoline, minimum 91 octane (Octane rating may vary by region, consult manual)

Oil Capacity:

Approx. 3.0 US quarts (2.8 Liters) for total system including transmission

Oil Type Specification:

Harley-Davidson SYN3 or approved SAE 20W50 motorcycle oil meeting Harley-Davidson P/N 63796-04

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive Type:

Duplex chain, rubber isolated chain drive

Final Drive Type:

Belt drive

Clutch Type:

Wet, multi-plate, hydraulic actuation

Transmission Oil Capacity:

Included in overall engine oil capacity, separate drain and fill points for transmission gear lubricant.

📐 Dimensions

Overall Length:

Approx. 92.5 inches (2350 mm)

Seat Height Unladen:

Approx. 26.0 inches (660 mm)

Ground Clearance:

Approx. 4.5 inches (115 mm)

Dry Weight:

Approx. 575 lbs (261 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 975 lbs (442 kg)

Fuel Tank Capacity:

5.0 US gallons (18.9 Liters)

🛡️ Safety Features

Safety Ratings Motorcycle:

Motorcycle safety is typically assessed by rider behavior and adherence to road regulations; specific crash test ratings are not applicable in the same manner as automobiles.

Braking System:

Dual-piston front and rear disc brakes, hydraulic actuation. Optional ABS available on some models/trims.

Lighting:

Halogen headlamp, LED taillight, amber incandescent front and rear turn signals.

Frame Construction:

Steel frame and swingarm providing structural integrity.

💡 Technology Features

Infotainment System:

Base models typically feature a minimalist dashboard with analog speedometer and indicator lights. Premium models may offer an integrated radio or allow for aftermarket audio system installation. This manual would cover any factory-fitted electrical components.

Driver Assistance Features:

Limited to standard motorcycle safety features like robust braking and stable chassis. ABS was an option and would be detailed if present.

Connectivity Features:

No advanced connectivity features (e.g., Bluetooth, smartphone integration) typically found on this model year.

🔧 Maintenance

Initial Service:

First service typically around 1,000 miles (1600 km)

Routine Maintenance Intervals:

Generally every 5,000 miles (8,000 km) for oil changes, inspections, and lubrication. Specific intervals for other components (e.g., spark plugs, primary chain adjustment) are detailed in the manual.

Primary Chain Case Oil:

Harley-Davidson Primary Chaincase Lubricant (P/N 99850-04) or equivalent SAE 80W-90 gear oil meeting HD spec.

Transmission Oil:

Same as primary chaincase oil (SAE 80W-90 gear oil)

Brake Fluid Type:

DOT 4 brake fluid (refer to manual for specific formulation if required).

Common Wear Items:

Clutch plates, drive belt, tires, brake pads, fork seals, battery.

Potential Troubles:

EFI system diagnostics can require specialized tools; occasional electrical gremlins; drive belt tension monitoring is critical.

Oil Filter Part Number Example:

Harley-Davidson oil filter P/N 63731-36

📚 Vehicle History

Harley Davidson Legacy:

Long-standing American motorcycle manufacturer with a rich history dating back to 1903, renowned for its V-twin engines and cruiser culture.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running model families, evolving from lightweight performance bikes to the cruiser-focused models of the 21st century.

Xl1200C Positioning:

The 'Custom' variant emphasizes styling and rider comfort, often featuring a lower seat height and more chrome than base Sportster models.

Manufacturing Location:

Milwaukee, Wisconsin, USA (and potentially other Harley-Davidson facilities).

🏆 Awards & Recognition

Xl1200C Market Perception:

Consistently popular model within the cruiser segment, appreciated for its iconic styling and the Harley-Davidson ownership experience.

Owner Satisfaction General:

Harley-Davidson Sportsters generally receive high owner satisfaction for their character and customization potential, with maintenance satisfaction heavily reliant on quality of service.