🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200R

Year:

2009

Model Designation:

Sportster 1200 Roadster

Vin Prefix:

1HD1

👋 Introduction

Category:

Cruiser Motorcycle

Target Audience:

Harley-Davidson owners, independent repair shops, and DIY enthusiasts seeking in-depth repair and maintenance information.

Competitors At Time:

Victory Kingpin, Indian Chief (though typically higher displacement/price), some Japanese cruisers with larger V-twins.

Model Focus:

The XL1200R Roadster is characterized by its classic styling, higher performance tuning compared to other Sportsters of the era, and twin front disc brakes for improved stopping power.

📋 Manual Details

Primary Coverage:

Harley-Davidson XL1200R Roadster

Secondary Coverage Notes:

Likely applicable to other 2009 Sportster models (XL883, XL883R, XL883C, XL1200C, XL1200L, XL1200N) with shared components and systems, though specific variations may exist.

Total Pages:

846

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Evolution V-Twin Engine (1200cc)

Fuel System:

Carbureted (likely Keihin CV) and Fuel Injection (EFI) systems, fuel tank, fuel pump, lines, and filter.

Ignition System:

Electronic Ignition, spark plugs, coils, ignition module.

Transmission:

5-speed Manual Transmission, clutch, primary drive, final drive.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), instrumentation, wiring diagrams.

Brakes:

Front and rear hydraulic disc brakes, master cylinders, calipers, brake lines, pads, rotors, fluid specifications.

Suspension:

Front telescopic forks (including seal replacement and fluid level checks), rear shock absorbers, swingarm.

Steering:

Handlebars, steering head bearings, fork assembly.

Frame And Bodywork:

Frame, fenders, fuel tank, seat, side covers, handlebars, controls.

Wheels And Tires:

Wheel bearings, tire pressure specifications, tire replacement guidance.

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication (if applicable), brake fluid checks, tire pressure checks.

Major Repairs:

Engine disassembly and reassembly, transmission overhaul, clutch service, fork seal replacement, brake caliper rebuild, starter motor replacement.

Troubleshooting:

Diagnostic charts, common problems and their solutions for engine, electrical, and mechanical systems.

Electrical Diagnostics:

Wiring diagrams, testing procedures for sensors, actuators, and charging system components.

Component Replacement:

Step-by-step instructions for replacing various parts, including carburetors/fuel injectors, ignition coils, battery, lights, and controls.

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable for quick information retrieval (standard for quality PDF manuals).

Quality:

High Resolution - Suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

73.4 cubic inches (1202 cc)

Bore X Stroke:

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

Compression Ratio:

9.0:1 (typical for this era)

Horsepower:

Approximately 65-70 HP (estimated, actual may vary slightly by specific configuration and dyno).

Torque:

Approximately 70-75 ft-lbs (estimated, actual may vary slightly by specific configuration and dyno).

Fuel Delivery:

Keihin CV 40mm Carburetor (for carbureted models) or Electronic Fuel Injection (EFI) system. The 'R' model often featured a specific fuel map or tuning for performance.

Fuel Type:

Unleaded gasoline, minimum 87 octane (91 AKI).

Oil Type:

Harley-Davidson recommended V-Twin specific 20W50 motorcycle oil, or equivalent meeting API SG or higher, JASO FD/FE.

Oil Capacity:

Approx. 3 quarts (2.8 liters) with filter change. (Manual will specify exact quantity).

🔧 Transmission

Type:

5-speed constant mesh

Primary Drive:

Chain, 1.406 ratio (32/23)

Final Drive:

Belt drive, 3.15:1 ratio (61/19 final sprocket)

Clutch Type:

Wet, multi-plate, cable-actuated

Transmission Oil Capacity:

Approx. 2.6 pints (1.2 liters) of Harley-Davidson recommended transmission lubricant (e.g., Harley-Davidson Formula + or Syn3, or equivalent SAE 80W-90 GL-4 gear oil).

📐 Dimensions

Length:

Approx. 90.0 inches (2286 mm)

Width:

Approx. 33.0 inches (838 mm)

Height:

Approx. 47.5 inches (1207 mm)

Front Tire:

100/90-19 57H

Rear Tire:

150/80-16 71H

Wheelbase:

Approx. 60.0 inches (1524 mm)

Dry Weight:

Approx. 556 lbs (252 kg)

Gross Vehicle Weight Rating:

Approx. 935 lbs (424 kg)

🛡️ Safety Features

Crash Testing:

Motorcycles are generally not subjected to standardized crash testing like automobiles. Safety focus is on rider protection and vehicle dynamics.

Braking:

Dual front hydraulic disc brakes and single rear hydraulic disc brake for enhanced stopping power, a key feature of the 'R' model.

Lighting:

Halogen headlight, LED taillight and brake light, amber turn signals.

Ergonomics:

Forward-mounted foot controls and a more aggressive riding posture contribute to rider control.

💡 Technology Features

Audio System:

Base models typically did not include a factory-installed audio system. Aftermarket integration is common.

Rider Aids:

No advanced electronic rider aids such as ABS or traction control were standard on this model.

Connectivity Features:

No integrated smartphone connectivity or Bluetooth features.

Dashboard Features:

Analog speedometer with integrated LCD display for odometer, trip meter, clock, and gear indicator (on some models). Tachometer often mounted separately or on handlebars.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1600 km) or 1 month, whichever comes first (includes oil change, filter change, inspection).

Routine Oil Change:

Every 5,000 miles (8000 km) or 12 months, whichever comes first. (Manual will confirm specific interval).

Spark Plug Replacement:

Typically every 10,000 - 15,000 miles (16,000 - 24,000 km). (Manual will confirm).

Belt Inspection Tension:

Every 2,500 miles (4000 km) or 6 months. (Manual will confirm).

Engine Oil Grade:

20W50 (Harley-Davidson recommended or equivalent meeting API SG+, JASO FD/FE).

Transmission Oil Grade:

SAE 80W-90 GL-4 gear oil (Harley-Davidson Formula+ or Syn3 recommended).

Primary Chain Case Oil:

Typically shares engine oil or requires specific primary lubricant. (Manual will confirm).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Harley-Davidson Factory Service Manual will specify viscosity and type (e.g., Type E or equivalent).

Common Wear Items:

Clutch plates, brake pads, fork seals, battery, wheel bearings.

Electrical Potential Issues:

Voltage regulator failure, stator output degradation, starter solenoid issues are known potential issues on Harley-Davidson models of this era.

Carburetor Tuning:

CV carburetors can require fine-tuning for optimal performance, especially after modifications or at different altitudes.

📚 Vehicle History

Brand History:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser/custom style motorcycles.

Sportster Lineage:

The Sportster platform has been in continuous production since 1957, evolving from its original OHV design to the Evolution engine, which debuted in 1986.

Xl1200R Introduction:

The XL1200R ('Roadster') variant was introduced to offer a sportier, more performance-oriented Sportster, often featuring dual front disc brakes and more aggressive styling than other Sportster models.

Manufacturing Location:

United States (Milwaukee, Wisconsin, and Kansas City, Missouri assembly plants).

🏆 Awards & Recognition

Motorcycle Awards:

Specific awards for the 2009 XL1200R are not prominently documented in industry publications, but the Sportster line generally receives praise for its iconic styling and V-twin character. Individual reviews often highlight its performance relative to other Sportsters.