Target Audience:
Harley-Davidson XL1200C Sportster Custom owners, independent repair shops, and motorcycle enthusiasts performing their own maintenance and repairs.
Value Proposition:
Provides authorized service procedures and specifications, offering a cost-effective alternative to dealership servicing and ensuring correct maintenance and repair for optimal performance and longevity.
Manual Strengths:
Detailed step-by-step instructions, clear diagrams and illustrations, comprehensive electrical schematics, troubleshooting guides, torque specifications, and maintenance schedules specific to the 2007 XL1200C.
Engine System:
Engine disassembly, assembly, tuning, diagnosis, cooling system (air-cooled), lubrication system, fuel injection (EFI), ignition system, exhaust system, emissions control.
Transmission Drivetrain:
Clutch, gearbox (5-speed), primary drive, final drive (belt), troubleshooting, adjustments, lubrication.
Chassis Frame:
Frame inspection, welds, mounts, steering head bearings, fork assembly, swingarm, rear suspension (shocks), wheel bearings.
Braking System:
Front and rear brake calipers, master cylinders, hydraulic lines, brake pads, rotors, fluid types, bleeding procedures, troubleshooting.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting (headlight, taillight, indicators), instrumentation, wiring diagrams, fuses, relays, diagnostics.
Fuel System:
Fuel tank, fuel pump, fuel injectors, throttle body, fuel pressure regulator, diagnostics, cleaning procedures.
Bodywork Trim:
Fenders, fuel tank, seat, handlebars, controls, mirrors, emblems, disassembly and reassembly of cosmetic components.
Maintenance Tasks:
Routine maintenance checks, oil changes, filter replacements (oil, air), spark plug replacement, brake fluid flush, chain adjustment (if applicable, though this model uses a belt), tire pressure checks, battery maintenance.
Repair Tasks:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnosis and replacement, fuel system servicing, exhaust system repairs.
Troubleshooting:
Diagnostic charts for common symptoms, electrical system troubleshooting, engine performance issues, starting problems, braking irregularities.
Special Tools:
Identification of required Harley-Davidson specific tools and general automotive tools.
Depth Level:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, clearances, and diagnostic procedures.
Engine Type:
Air-cooled, Evolution V-Twin
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Horsepower Estimate:
~65-70 HP (at crankshaft, estimated)
Torque Estimate:
~70-75 lb-ft @ 3500 RPM (at crankshaft, estimated)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON)/91 AKI
Oil Type:
Harley-Davidson Genuine V-Twin 20W-50, or equivalent API CI-4 rated synthetic motorcycle oil.
Oil Capacity:
3.0 US qt (2.8 L) with filter change
Crash Test Ratings:
N/A (Motorcycles are not typically rated by standard automotive safety organizations like NHTSA or IIHS)
Braking System:
Dual-piston front caliper with 11.5-inch disc; Single-piston rear caliper with 11.5-inch disc.
Lighting:
Halogen headlight, LED taillight, amber incandescent front and rear turn signals.
Frame Construction:
Steel tube frame with cradle.
Wheels Tires:
Spoked wheels, typically 16-inch front and rear. Tire sizes: Front 130/90B16, Rear 150/80B16.
Instrumentation:
Analog speedometer, tachometer (optional on some trims, but usually present on XL1200C), fuel gauge, odometer, trip meter, indicator lights (oil pressure, battery, high beam, turn signals, neutral).
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on 2007 models, not standard.
Diagnostic Ports:
Features a diagnostic port for connecting to Harley-Davidson's Digital Technician for advanced diagnostics and tuning.
Oil Change Interval:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Primary Chain Tension:
Check and adjust every 2,500 miles (4,000 km) or as needed.
Spark Plug Replacement:
Inspect at 5,000 miles (8,000 km), replace as needed. Replace iridium plugs around 20,000-30,000 miles.
Brake Fluid Flush:
Every 2 years or as per manual recommendation.
Belt Drive Inspection:
Inspect tension and condition regularly, typically every 5,000 miles.
Engine Oil Specification:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API CI-4 synthetic)
Transmission Oil Specification:
Harley-Davidson Genuine Formula + Transmission Lubricant (or equivalent SAE 50 motorcycle transmission oil)
Primary Chain Case Oil:
Harley-Davidson Genuine Formula + Transmission Lubricant (or equivalent SAE 50 motorcycle transmission oil)
Brake Fluid Specification:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Primary chain tensioner (early models had a hydraulic tensioner that could wear), wheel bearings, steering head bearings, brake pads, belt wear (if improperly tensioned).
Engine Performance Notes:
Some owners report a need for recalibration of the fuel system (e.g., with a fuel management system) to optimize performance, especially with exhaust modifications. Intermittent starting issues can sometimes be related to battery health or starter solenoid.
Harley Davidson History:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser-style motorcycles. The Sportster line, introduced in 1957, is one of the longest-running motorcycle model names in history.
Sportster Line Evolution:
The Sportster has evolved significantly over the decades, transitioning from its earlier Ironhead engines to the Evolution engine. The XL1200C (Custom) variant typically features more chrome, a larger front wheel (16-inch in this era), and a relaxed riding posture.
Model Year Significance:
The 2007 model year saw Harley-Davidson's continued refinement of the Sportster platform, with the 1200 Custom embodying the classic cruiser aesthetic. This year also marked the widespread adoption of Electronic Fuel Injection across the Harley-Davidson lineup.
