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Harley Davidson XL1200C 2009 Workshop Service Repair Manual
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Basic Information Identification Make: Harley-Davidson Model: XL1200C Year: 2009 Codes Chassis Code: XL1200C Engine Code: Evolution 1200 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Owners and technicians of the...
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| Basic Information | |
| Identification | |
| Make: | Harley-Davidson |
| Model: | XL1200C |
| Year: | 2009 |
| Codes | |
| Chassis Code: | XL1200C |
| Engine Code: | Evolution 1200 |
| Introduction | |
| Market Position | |
| Segment: | Cruiser Motorcycle |
| Target Audience: | Owners and technicians of the Harley-Davidson XL1200C 2009 seeking repair, maintenance, and diagnostic information. |
| Competitive Analysis | |
| Manual Value: | Provides factory-level accuracy, covering all aspects of the motorcycle, ensuring correct and efficient repairs, saving significant costs compared to dealership labor. |
| Key Features | |
| Completeness: | This is the COMPLETE official full factory service repair manual, offering exhaustive information. |
| Usability: | Downloadable PDF format allows for selective printing and easy navigation through searchable text. |
| Authority: | Directly from factory sources, ensuring accuracy of procedures, specifications, and diagrams. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Harley-Davidson XL1200C 2009 |
| Page Count | |
| Estimated Pages: | Hundreds of pages (specific count not provided, but implies comprehensive coverage) |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Full engine overhaul, internal component inspection and repair, cylinder head, piston, connecting rod, crankshaft service. |
| Fuel System: | Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines, and related components. |
| Ignition System: | Ignition module, spark plugs, ignition coils, wiring, and troubleshooting. |
| Transmission Drivetrain: | 5-speed constant mesh transmission, clutch operation and service, primary drive, final drive belt, and related components. |
| Electrical System: | Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instruments, switches, relays, and fuses. |
| Chassis Frame: | Frame inspection, front forks, rear shock absorbers, swingarm, steering head bearings, and wheel bearings. |
| Brakes: | Front and rear brake systems, master cylinders, calipers, brake pads, rotors, brake lines, and bleeding procedures. |
| Wheels Tires: | Wheel removal and installation, tire mounting and balancing, spoke tension (if applicable to specific sub-models). |
| Bodywork Fittings: | Fenders, fuel tank, seat, handlebars, control levers, mirrors, and other body components. |
| Diagnostics: | Troubleshooting charts, fault codes (if applicable to the diagnostic system), symptom-based diagnostics. |
| Procedures Included | |
| Preventative Maintenance: | Oil changes, filter replacements, chain/belt adjustment and lubrication, brake fluid changes, spark plug replacement, air filter cleaning/replacement. |
| Routine Maintenance: | General inspection, lubrication points, safety checks. |
| Troubleshooting: | Step-by-step diagnostic procedures for common and uncommon issues across all systems. |
| Repair Procedures: | Detailed, step-by-step instructions for disassembling, inspecting, repairing, and reassembling all major components and systems. |
| Component Replacement: | Instructions for replacing parts such as brake pads, clutch plates, bearings, seals, electrical components, etc. |
| Wiring Diagrams: | Comprehensive electrical wiring diagrams for accurate troubleshooting and repair. |
| Torque Specifications: | Critical torque values for all fasteners to ensure proper assembly and prevent component failure. |
| Technical Depth | |
| Depth: | Comprehensive factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. |
| Diagnostic Tools: | Information on any specialized tools or diagnostic equipment required for certain procedures (e.g., EFI tuning tools). |
| Rebuild Procedures: | Detailed instructions for complete engine, transmission, and other major component rebuilds. |
| Manual Specifications | |
| File Format | |
| Format: | PDF (Portable Document Format) |
| Print Quality | |
| Printability: | High-resolution, suitable for printing individual sections or the entire manual. |
| Binding Type | |
| Binding: | N/A (Digital download, binding is user-dependent upon printing) |
| Paper Type | |
| Paper Recommendation: | N/A (Digital download, paper type is user-dependent upon printing) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Air-cooled, Evolution® V-Twin |
| Displacement: | 1200 cc (73.2 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 Estimated: | Approximately 65-70 HP (specific figure may vary slightly and is detailed in manual) |
| Torque Estimated: | Approximately 71 ft-lbs @ 3200 RPM (65 ft-lbs @ 3500 RPM for earlier 1200s, 2009 will be higher, exact figure in manual) |
| Fuel System | |
| Fuel Delivery: | Electronic Sequential Port Fuel Injection (ESPFI) |
| Fuel Type: | Unleaded gasoline |
| Fuel Tank Capacity: | 4.5 gallons (17.0 L) |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed, Constant Mesh |
| Primary Drive: | Duplex chain, 34/46 ratio |
| Final Drive: | Belt, 32/66 ratio |
| Features | |
| Clutch Type: | Wet, multi-plate |
| Transmission Fluid Type: | Harley-Davidson SYN3 or equivalent SAE 20W50 Synthetic (manual will specify exact type and capacity) |
| Dimensions | |
| Exterior | |
| Length: | 90.4 in (2296 mm) |
| Width: | 35.9 in (912 mm) |
| Height: | 48.5 in (1232 mm) |
| Wheelbase: | 60.0 in (1524 mm) |
| Ground Clearance: | 4.8 in (122 mm) |
| Weights | |
| Dry Weight: | 575 lbs (261 kg) |
| Wet Weight Estimated: | Approximately 600-610 lbs (manual will provide precise figure) |
| Safety Features | |
| Ratings | |
| Safety Standards: | Meets applicable federal safety standards for motorcycles of its type. Manual provides details on component specifications related to safety. |
| Active Features | |
| Braking System: | Dual disc front brake, single disc rear brake with hydraulic actuation. ABS was optional for 2009 XL1200C models, and if equipped, will be detailed in the manual. |
| Passive Features | |
| Lighting: | Halogen headlamp, LED tail lamp, front and rear turn signals. |
| Technology Features | |
| Infotainment | |
| Instrumentation: | Analog speedometer with integrated LCD display for odometer, trip meter, clock, and gear indication. Manual details instrumentation functions. |
| Driver Assistance | |
| ABS: | Anti-lock Braking System (ABS) was an optional feature for the 2009 XL1200C. The manual will detail its operation and service if equipped. |
| Connectivity | |
| Diagnostics Port: | Likely features a diagnostic port for electronic troubleshooting, with the manual providing guidance on its use. |
| Maintenance | |
| Service Intervals | |
| First Service: | 1,000 miles (1,600 km) or 6 months, whichever comes first. (Detailed schedule in manual) |
| Subsequent Service: | Every 5,000 miles (8,000 km) or 12 months, whichever comes first. (Detailed schedule in manual) |
| Fluid Specifications | |
| Engine Oil: | Harley-Davidson SYN3 or equivalent SAE 20W50 Synthetic. Capacity: 3.0 US qt (2.8 L) (check manual for exact capacity and filter part number). |
| Primary Chain Case Oil: | Harley-Davidson primary fluid or equivalent SAE 80W-90 Hypoid Gear Oil. Capacity: 2.4 US qt (2.3 L) (check manual for exact capacity and filter part number). |
| Transmission Oil: | Harley-Davidson SYN3 or equivalent SAE 20W50 Synthetic. Capacity: 0.9 US qt (0.85 L) (check manual for exact capacity and filter part number). |
| Brake Fluid: | DOT 4 fluid (check manual for specific recommendations and bleeding procedures). |
| Known Issues | |
| Common Wear Items: | Clutch friction plates, brake pads, wheel bearings, steering head bearings, drive belt. Manual covers inspection and replacement. |
| Electrical Gremlins: | While generally robust, older Sportsters can develop intermittent electrical issues. The manual's wiring diagrams and diagnostic procedures are crucial. |
| Engine Vibration: | Characteristic of V-Twins; manual covers engine mounts and balancing for optimal performance and longevity. |
| Vehicle History | |
| Brand Heritage | |
| Heritage: | Harley-Davidson, a storied American motorcycle manufacturer with a legacy dating back to 1903, known for its V-twin engines and iconic styling. |
| Model Evolution | |
| Sportster Lineage: | The XL1200C is part of the Sportster family, which has been in continuous production since 1957, evolving from lightweight customs to powerful cruisers. |
| Xl1200C Custom: | The 'C' designation signifies the Custom model, typically featuring more chrome, a larger front wheel, and often a more relaxed riding position, emphasizing style. |
| Production | |
| Production Years: | The XL1200C model has been produced in various forms since the late 1980s, with the 2009 model representing a specific iteration of the Sportster platform. |
| Awards & Recognition | |
| Recognitions | |
| Model Awards: | Specific awards for the 2009 XL1200C are less commonly published than for cars. However, the Sportster line generally receives positive reviews for its classic styling and customizable nature. Manual provides the technical foundation for maintaining these award-worthy qualities. |