🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2010

Chassis Code:

XL1200C

Engine Code:

Evolution V-Twin (1200cc)

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a customizable, classic cruiser experience with modern fuel injection and braking.

Competitors:

Other V-twin cruisers from American and Japanese manufacturers, such as Indian Scout, Yamaha Bolt, and older Harley-Davidson Sportster models.

Styling:

Classic Harley-Davidson styling with ample chrome, teardrop fuel tank, and low seat height.

Customization:

Designed for extensive customization with a wide range of factory and aftermarket accessories.

Performance:

Torquey V-twin engine suitable for relaxed cruising and spirited acceleration.

📋 Manual Details

Region:

Global (specifications may vary slightly by market)

Pages:

825

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Complete overhaul, diagnosis, and repair of the Evolution 1200cc V-Twin engine (carbureted and fuel injected variants applicable to the 2010 model year, primarily EFI).

Transmission:

Service, inspection, and repair of the 5-speed constant mesh transmission and clutch assembly.

Drivetrain:

Inspection and maintenance of the belt drive system, rear pulley, and wheel bearings.

Fuel System:

Diagnosis and repair of the Electronic Fuel Injection (EFI) system, throttle body, fuel pump, fuel filter, and fuel lines.

Electrical System:

Comprehensive coverage of ignition system, starting system, charging system (alternator, regulator/rectifier), battery, lighting, and all related wiring harnesses and components.

Brakes:

Service and repair of front and rear hydraulic disc brakes, including caliper overhaul, pad replacement, fluid flushing, and ABS system (if equipped).

Suspension:

Front fork servicing (oil change, seal replacement), rear shock absorber maintenance and replacement, and suspension adjustments.

Chassis Frame:

Frame inspection, steering head bearing service, and general chassis component maintenance.

Bodywork Trim:

Removal and installation of fenders, fuel tank, seat, handlebars, mirrors, and other trim components.

Diagnostics:

Troubleshooting guides, diagnostic codes (DTCs), and flowcharts for common issues across all systems.

Maintenance:

Routine maintenance procedures including oil changes, filter replacements, spark plug replacement, brake fluid changes, and belt tension checks.

Repair:

Step-by-step repair instructions for engine, transmission, electrical, brake, suspension, and chassis components.

Troubleshooting:

Detailed troubleshooting guides for diagnosing and resolving performance issues, electrical faults, and mechanical problems.

Rebuilds:

Comprehensive instructions for engine and transmission rebuilds, including torque specifications and clearances.

Adjustments:

Procedures for clutch adjustment, throttle cable adjustment, brake lever adjustment, and suspension tuning.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair and maintenance procedures.

Depth:

Advanced diagnostic and repair procedures, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete disassembly, assembly, and calibration.

📊 Manual Specifications

Format:

PDF

Searchability:

Fully searchable text content for quick information retrieval.

Resolution:

High-resolution scans for clear text and diagrams.

Illustrations:

Includes detailed diagrams, exploded views, and photographic illustrations.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1202 cc (73.3 cubic inches)

Bore X Stroke:

3.537 in x 3.813 in (90 mm x 97 mm)

Compression Ratio:

9.7:1

Horsepower:

Approx. 66 HP @ 5600 RPM (Manufacturer claim, actual may vary)

Torque:

Approx. 71 ft-lbs @ 3500 RPM (Manufacturer claim, actual may vary)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50, or equivalent SAE 20W-50 API SG or higher approved motorcycle oil.

Oil Capacity:

3.0 US qt (2.8 L) with filter change.

🔧 Transmission

Transmission Type:

5-speed, constant mesh

Optional Transmission:

N/A (All 2010 XL1200C models came with the 5-speed transmission)

Clutch Type:

Wet, multi-plate

Primary Drive:

46/30 Silent Gear Primary Drive

Final Drive:

Carbon fiber belt, 32/30 ratio

Transmission Fluid:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant, or equivalent SAE 85W-90 GL-5 gear oil.

Transmission Fluid Capacity:

Approx. 26 US fl oz (0.77 L).

📐 Dimensions

Length:

90.5 in (2299 mm)

Width:

34.6 in (879 mm)

Height:

47.1 in (1196 mm)

Seat Height Unladen:

25.5 in (648 mm)

Ground Clearance:

4.8 in (122 mm)

Wheelbase:

60.0 in (1524 mm)

Fuel Capacity:

4.5 US gal (17.0 L)

Dry Weight:

570 lbs (259 kg)

Gross Vehicle Weight Rating:

963 lbs (437 kg)

Front Tire:

MT90B16 72H

Rear Tire:

150/80B16 77H

Wheel Type:

Chrome cast aluminum

Wheelbase Bolt Pattern:

5x114.3mm

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subject to the same NCAP-style crash testing as cars. Safety relies on rider skill and protective gear.

Braking System:

Dual-piston front caliper, single-piston rear caliper. Optional ABS available on some models.

Lighting:

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

Frame Construction:

Steel frame and swingarm designed for stability and handling.

💡 Technology Features

Instrumentation:

Analog speedometer with integrated LCD display showing odometer, trip meter, clock, and gear indicator. Warning lamps for oil pressure, check engine, and battery.

Audio System:

N/A (No factory integrated audio system on standard models, though aftermarket options are prevalent).

ABS:

Optional Anti-lock Braking System (ABS) available on some trims for enhanced braking control.

Diagnostic Interface:

On-board diagnostics (OBD-II compliant for EFI systems), accessible via proprietary Harley-Davidson diagnostic tools.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 6 months. Includes engine oil and filter change, primary chaincase oil change, check clutch, throttle, and brake controls, inspect tires, and check all external fasteners.

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months. Includes engine oil and filter change, primary chaincase oil change, inspect and adjust belt tension, inspect brake pads and fluid, inspect and lubricate cables, check all fasteners, inspect spark plugs.

Spark Plug Replacement:

Every 10,000 miles (16,000 km) or as needed.

Brake Fluid Flush:

Every 24 months, regardless of mileage.

Engine Oil:

Harley-Davidson Genuine V-Twin 20W-50, or SAE 20W-50 API SG or higher approved motorcycle oil. Capacity: 3.0 US qt (2.8 L) with filter.

Primary Chaincase Oil:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant, or SAE 85W-90 GL-5 gear oil. Capacity: Approx. 26 US fl oz (0.77 L).

Brake Fluid:

DOT 4 Hydraulic Brake Fluid (if equipped with ABS, consult manual for specific type).

Fork Oil:

Harley-Davidson Type E (or equivalent suspension fluid with similar viscosity).

Common Issues:

Some owners report potential issues with electrical connections (especially aftermarket accessories), clutch cable adjustment, and fuel line leaks. Regular maintenance as per the manual is crucial for longevity. Vibration can be noticeable at higher RPMs due to the V-twin nature.

📚 Vehicle History

Manufacturer:

Harley-Davidson Motor Company

Heritage:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser styling.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running motorcycle model. The XL1200C Custom is a modern iteration focusing on classic styling and rider customization.

2010 Updates:

For 2010, the XL1200C received key updates including standard Electronic Fuel Injection (EFI), a new frame for improved handling, and revised ergonomics.

Manufacturing Location:

United States

🏆 Awards & Recognition

Industry Recognition:

Harley-Davidson motorcycles, including the Sportster line, have consistently received accolades for their iconic styling, V-twin performance, and rider community engagement.

Customer Satisfaction:

Generally high customer satisfaction, particularly among riders who value the Harley-Davidson experience and customization potential. Reliability is dependent on adherence to the maintenance schedule.

Emissions:

Compliant with US EPA and California ARB emissions standards for the 2010 model year.