Positioning:
The Harley-Davidson XL1200C Sportster Custom is a classic cruiser known for its customization potential and iconic V-twin engine. This manual caters to owners and technicians who value meticulous detail in maintaining and repairing this specific model.
Competitors:
Direct competitors in its class during this era included models from Indian Motorcycle, Triumph Bonneville, and various Japanese cruisers, though the Sportster held a unique position due to its established brand loyalty and V-twin character.
Vehicle Appeal:
Timeless styling, accessible V-twin power, rider-friendly ergonomics, and extensive aftermarket support.
Manual Value Proposition:
Provides factory-accurate procedures, saving time and money on repairs, ensuring longevity and optimal performance of the motorcycle.
Engine:
Complete overhaul, troubleshooting, diagnostics, specific component repair (e.g., cylinders, pistons, camshafts, valves, lubrication system, cooling system - air-cooled)
Transmission:
Service, repair, troubleshooting, clutch operation, gearshift mechanism, primary drive, final drive (belt/chain)
Fuel System:
Carburetor (Keihin CV), fuel pump, fuel lines, fuel tank, emissions controls
Electrical System:
Ignition system (coil, spark plugs, timing), starting system, charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), instrumentation, battery maintenance, wiring diagrams
Brakes:
Front and rear brake system service, bleeding, pad replacement, caliper repair, master cylinder maintenance
Suspension:
Front fork (telescopic), rear shock absorbers, servicing, adjustment, replacement
Chassis And Body:
Frame, handlebars, controls, seating, fenders, fuel tank removal/installation, exhaust system
Wheels And Tires:
Tire inspection, replacement, wheel bearing service, spoke tensioning (if applicable)
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, drive belt/chain adjustment and lubrication, brake fluid checks, tire pressure checks
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common issues
Repair Procedures:
Step-by-step instructions for disassembly, assembly, and replacement of all major components
Specifications And Tolerances:
Torque specifications, critical measurements, clearances, fluid capacities
Wiring Diagrams:
Detailed electrical schematics for all systems
Depth:
Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts
Engine Type:
Evolution V-Twin, Air-Cooled
Displacement:
1200cc (73.3 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Valvetrain:
Pushrod-actuated, overhead valves (OHV) with 2 valves per cylinder
Engine Oil Type:
Harley-Davidson SAE 20W50 or equivalent motorcycle-specific oil
Horsepower Estimate:
Approx. 65-70 HP (dependent on tuning and exact configuration)
Torque Estimate:
Approx. 70-75 lb-ft @ 3200 RPM
Fuel Delivery:
Carburetor (Keihin 40mm CV - Constant Velocity)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
4.0 US gallons (15.1 L)
Transmission Type:
5-speed Manual Constant Mesh
Clutch:
Wet, multi-plate, diaphragm spring
Primary Drive:
Conical Hub, Helical Groove, 1.667:1 ratio
Final Drive:
Carbon fiber reinforced belt, 32/66 tooth ratio (2.06:1)
Transmission Oil Type:
Harley-Davidson Transmission Lubricant SAE 80W-90 or equivalent
Crash Test Rating:
N/A (Motorcycle safety is primarily based on rider skill and design features)
Braking System:
Hydraulic disc brakes front and rear
Headlight:
Halogen 55W/60W
Taillight:
Incandescent, dual filament
Frame Construction:
Steel, mild cradle frame
Instrumentation:
Speedometer, tachometer, fuel gauge, indicator lamps
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months
Drive Belt Tension Check:
Every 10,000 miles (16,000 km)
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Engine Oil Capacity:
3.0 US quarts (2.8 L) with filter change
Transmission Oil Capacity:
24 US fluid ounces (0.7 L)
Primary Chaincase Oil Capacity:
24 US fluid ounces (0.7 L)
Common Wear Items:
Clutch plates, drive belt, brake pads, fork seals, wheel bearings.
Potential Electrical Quirks:
While generally reliable, attention to grounds, connectors, and the regulator/rectifier is sometimes needed. The manual's wiring diagrams are crucial here.
Carburetor Tuning:
The Keihin CV carburetor can require fine-tuning for optimal performance, especially with aftermarket modifications. This manual details the adjustment procedures.
Brand Origin:
Founded in 1903 in Milwaukee, Wisconsin, USA, Harley-Davidson is one of the oldest motorcycle manufacturers in the world.
Sportster Lineage:
The Sportster line was introduced in 1957, evolving from the K-model. The XL1200C represents a modern iteration focused on a classic cruiser aesthetic.
2004 Updates:
The 2004 model year marked a significant update for the Sportster line, including the introduction of the rubber-mounted Evolution engine for reduced vibration, a new frame design, and updated electrical components, which this manual thoroughly covers.
Manufacturing Location:
Milwaukee, Wisconsin, USA
