Harley Davidson XL1200C Motorcycle Complete Workshop Service Repair Manual 2009

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Year: 2009 Product Type: Workshop Service Repair Manual Product Format: Downloadable 👋 Introduction Market Position Vehicle Segment: Cruiser Motorcycle Target...

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标签: 2009 Harley Davidson Misc Motorcycle Motorcycles XL1200C

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

Product Type:

Workshop Service Repair Manual

Product Format:

Downloadable

👋 Introduction

Market Position

Vehicle Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a classic cruiser aesthetic with modern performance, owners who perform their own maintenance and repairs.

Competitive Analysis

Key Competitors 2009:

Indian Chief, Triumph Bonneville America, Kawasaki Vulcan 900 Classic, Yamaha V-Star 950

Key Features

Xl1200C Distinguishing Features:

Spoked wheels, chrome accents, low seat height, forward-mounted foot controls, robust 1200cc Evolution engine, wide handlebars.

Manual Value Proposition:

Empowers owners with the knowledge to maintain and repair their Harley-Davidson, saving time and money, ensuring proper operation and longevity.

📋 Manual Details

Coverage Areas

Overall Coverage:

Complete Service & Repair Procedures

Page Count

Estimated Pages:

Refer to actual manual for exact count

Manual Type

Manual Classification:

Workshop Service Manual / Repair Manual

Language

Primary Language:

English

Format

Digital Format:

PDF (implied by downloadable)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine assembly, disassembly, tuning, lubrication, cooling, fuel delivery, ignition system, starting system, charging system, emissions control

Drivetrain Systems:

Clutch, transmission, final drive, belt drive maintenance and repair

Chassis Systems:

Frame, suspension (front fork, rear shocks), steering, wheels, tires, brakes (front and rear hydraulic disc brakes), controls

Electrical Systems:

Wiring diagrams, lighting system, instrumentation, battery, starter motor, alternator, ignition, accessories, troubleshooting electrical faults

Bodywork And Accessories:

Body panels, fenders, fuel tank, seat, handlebars, mirrors, exhaust system, fairings (if applicable)

Procedures Included

Maintenance Procedures:

Routine maintenance, oil changes, filter replacements, brake fluid changes, tire pressure checks, chain/belt adjustment, lubrication points

Repair Procedures:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service, electrical component diagnostics and replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, common problems and solutions

Technical Adjustments:

Carburetor/fuel injection adjustment, ignition timing, clutch adjustment, throttle cable adjustment

Special Tools:

Identification and usage of specialized tools required for specific repairs

Technical Depth

Diagnostics Level:

Detailed diagnostic procedures for all major systems

Rebuild Scope:

Comprehensive engine and transmission rebuild instructions

Electrical Troubleshooting Detail:

In-depth wiring diagrams and fault isolation procedures

Torquew Specifications:

Critical torque specifications for all fasteners

Clearances And Tolerances:

Precise measurements for component clearances and tolerances

📊 Manual Specifications

File Format

Digital File Type:

Print Quality

Image Resolution:

High-resolution, suitable for printing (typical for professional service manuals)

Binding Type

Physical Manual Binding:

N/A (Downloadable Format)

Paper Type

Physical Manual Paper:

N/A (Downloadable Format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Evolution (Big Twin variant optimized for Sportster chassis)

Engine Type:

Air-cooled, 45-degree V-twin, four-stroke

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Performance

Horsepower Approximate:

65-70 HP (est. at crank)

Torque Approximate:

70-75 lb-ft @ 3500 RPM (est. at crank)

Fuel System

Fuel Delivery System:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Premium unleaded gasoline, 91 octane minimum recommended

Ignition System

Ignition Type:

Electronic, high-performance

Lubrication System

Oil Type:

Harley-Davidson Genuine Motor Oil SAE 20W-50 or equivalent motorcycle-specific lubricant

Oil Capacity W Filter:

3.0 US quarts (2.8 liters)

🔧 Transmission

Standard

Transmission Type:

5-speed Constant Mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Carbon fiber reinforced belt, 132 tooth, 25mm width

Fluid Specifications

Transmission Fluid Type:

Harley-Davidson Formula+ (or suitable equivalent)

Transmission Fluid Capacity:

24 US fluid ounces (0.71 Liters)

📐 Dimensions

Exterior

Overall Length:

92.5 inches (2350 mm)

Overall Width:

36.4 inches (925 mm) (approx. handlebar width)

Overall Height:

47.1 inches (1196 mm)

Wheelbase:

60.0 inches (1525 mm)

Ground Clearance:

4.4 inches (112 mm)

Seat Height Laden:

26.2 inches (665 mm)

Weights

Dry Weight:

570 lbs (259 kg)

Gross Vehicle Weight Rating Gvwr:

932 lbs (423 kg)

Fuel Capacity:

4.0 US gallons (15.1 L)

Wheels And Tires

Front Tire Size:

100/90-19 57H

Rear Tire Size:

150/80B16 71H

Front Wheel Type:

Chrome, 19-inch, 16-spoke

Rear Wheel Type:

Chrome, 16-inch, 16-spoke

🛡️ Safety Features

Ratings

Safety Certification:

Meets FMVSS for motorcycles (US Market)

Active Features

Braking System:

Dual disc brakes: 292mm front, 292mm rear, hydraulic, dual-piston calipers

Lighting:

Halogen headlamp, LED tail/stop lamp, amber front and rear turn signals

Passive Features

Frame Construction:

Mild steel, tubular, cradle frame with forged steel downtubes

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer with integrated tachometer, odometer, trip meter, fuel gauge, and indicator lamps.

Driver Assistance

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature for the 2009 XL1200C, not standard.

Connectivity

Connectivity Features:

None in the modern sense (no Bluetooth, USB, or smartphone integration).

🔧 Maintenance

Service Intervals

First Service Mileage:

1,000 miles (1,600 km) or 6 months

Subsequent Service Mileage:

Every 5,000 miles (8,000 km) or 12 months thereafter

Fluid Specifications

Primary Chain Case Oil Type:

Harley-Davidson Formula+ or equivalent

Primary Chain Case Oil Capacity:

2.5 US quarts (2.4 Liters)

Brake Fluid Type:

DOT 4 hydraulic fluid (for clutch and brake systems, refer to manual for specific compatibility)

Fork Oil Type:

Harley-Davidson Genuine Fork Oil (Lightweight) or equivalent, viscosity typically 10W (check manual for exact spec)

Fork Oil Capacity Per Leg:

Approximately 8.7 US fl oz (257 ml) (check manual for exact specification)

Known Issues

Common Sportster Issues General:

Primary chain tensioner wear, oil leaks from engine seals, regulator/rectifier failures, clutch cable adjustment sensitivity.

2009 Specific Potential Issues:

Early ESPFI systems could sometimes be sensitive to atmospheric conditions or require specific tuning for optimal performance. Potential for wear on internal clutch components.

📚 Vehicle History

Brand Heritage

Harley Davidson Founding:

Founded in 1903, Milwaukee, Wisconsin.

Sportster Lineage:

The Sportster line originated in 1957, evolving from earlier OHV designs.

Model Evolution

Xl1200C Introduction Year:

The XL1200C variant was introduced in 1996.

2009 Updates:

Likely received minor refinements over previous years, potentially related to emissions, fuel injection tuning, or cosmetic updates.

Production

Manufacturing Location:

USA (Kansas City, Missouri or York, Pennsylvania typical)

🏆 Awards & Recognition

Recognitions

General Sportster Reputation:

Consistently praised for its classic styling, accessible riding position, and customization potential.

Ratings

Industry Reviews 2009:

Likely received positive reviews for its V-twin character, comfortable ride for a cruiser, and strong aftermarket support.

Certifications

Emissions Compliance:

Meets EPA and California Air Resources Board (CARB) emissions standards for its model year.