Harley Davidson XR1200 2009 Workshop Service Repair Manual
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Basic Information
Identification
Make:
Harley-Davidson
Model:
XR1200
Year:
2009
Vehicle Type:
Motorcycle
Generation
Generation Code:
XR1200 (First Generation)
Introduction
Market Position
Market Segment:
Performance Cruiser / Sportster Variant
Target Audience:
Harley-Davidson XR1200 owners, enthusiasts, independent mechanics
Competitive Analysis
Competitive Niche:
Bridged the gap between traditional Harley-Davidson cruisers and sportbikes, offering a more agile and performance-oriented experience.
Key Features
Product Value Proposition:
Comprehensive, official factory information for efficient maintenance and repair, saving costs compared to dealership service.
Delivery Method:
Instant download after payment, eliminating shipping delays and costs.
Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Additional Coverage:
Maintenance, Troubleshooting, Diagnostics, Electrical Systems, Wiring Diagrams
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as comprehensive)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Manual Coverage
Systems Covered
Engine Systems:
Fuel System, Cooling System, Engine Lubrication System, Engine Removal/Installation
Drivetrain Systems:
Clutch, Drive, Transmission, Final Drive
Chassis And Suspension:
Chassis, Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System, Wiring Diagram, Troubleshooting
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Adjustments
Repair Procedures:
Complete Disassembly and Reassembly, Component Overhauls, Component Replacement
Diagnostic Procedures:
Troubleshooting guides for common issues, electrical system diagnostics
Technical Depth
Depth:
In-depth, professional quality, suitable for DIY and experienced mechanics
Instruction Style:
Step-by-step instructions, detailed substeps, numbered instructions
Visual Aids:
Hundreds of photos, illustrations, drawings, enlarged insets for detail examination
Manual Specifications
File Format
File Type:
PDF
Compatibility:
All PC-based Windows operating systems, Mac OS
Print Quality
Printability:
Printable without restriction (entire manual or selected pages)
Binding Type
Binding Type:
Digital Download (printable for physical binding by user)
Paper Type
Paper Type:
N/A (Digital PDF)
Software Requirements
Reader Requirement:
Adobe PDF Reader
Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, pushrod OHV
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.43 in x 4.00 in (87 mm x 102 mm)
Compression Ratio:
10.0:1
Performance
Horsepower Rating:
Approx. 92 hp @ 7000 rpm (claimed)
Torque Rating:
Approx. 77.4 lb-ft @ 6000 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 89 octane (87 AKI)
Cooling System
Cooling Method:
Oil-cooled cylinders and heads
Transmission
Standard
Transmission Type:
5-speed constant mesh
Features
Clutch Type:
Clutched, wet, multi-plate
Primary Drive:
Gears, ratio 1.500
Final Drive:
Belt drive, ratio 2.75:1
Dimensions
Exterior
Length:
Approx. 85.2 in (2164 mm)
Width:
Approx. 35.6 in (904 mm)
Height:
Approx. 47.8 in (1214 mm)
Weights
Dry Weight:
Approx. 492 lbs (223 kg)
Gross Vehicle Weight Rating:
Approx. 930 lbs (422 kg)
Safety Features
Ratings
Safety Standards:
Compliant with applicable motorcycle safety regulations (specific ratings not detailed in product info).
Active Features
Braking System:
Dual 292 mm disc front brakes with 4-piston calipers, Single 292 mm disc rear brake with 2-piston caliper.
Passive Features
Lighting System:
Halogen headlamp, LED tail lamp, amber turn signals.
Technology Features
Infotainment
Instrumentation:
Analog tachometer and speedometer, digital odometer, trip meter, clock, fuel gauge, gear indicator.
Driver Assistance
ABS Availability:
Optional on some models/markets, but not standard on all 2009 XR1200s.
Connectivity
Diagnostic Port:
Proprietary diagnostic port for electronic diagnostics (covered in the manual).
Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals (typically 5,000 miles or annually).
Primary Chain Case Oil Change:
Refer to manual for specific intervals.
Spark Plug Replacement:
Refer to manual for specific intervals (e.g., 10,000-15,000 miles).
Fluid Specifications
Engine Oil Type:
Harley-Davidson SYN3 Full Synthetic Motor Oil or equivalent SAE 20W-50 API CI-4 or better.
Primary Chain Case Fluid:
Formula + Transmission Lubricant (or equivalent SAE 80W-90 API GL-5 gear oil).
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to specific caliper/master cylinder recommendations in manual).
Fork Oil Type:
Refer to manual for specific grade and type (e.g., SAE 15W).
Known Issues
Common Wear Items:
Clutch plates, belt drive wear, fork seals, fuel pump issues (in some instances).
Electrical Considerations:
Wiring harness integrity, voltage regulator/stator health are common checks for Harley-Davidson motorcycles.
Vehicle History
Brand Heritage
Brand Legacy:
Harley-Davidson, established 1903, renowned for V-twin motorcycles and a distinct American riding culture.
Model Evolution
Xr Series Heritage:
The XR1200 pays homage to Harley-Davidson's XR-750 flat track racing heritage, but adapted for street use.
Release Strategy:
Initially released in Europe in 2008, followed by the United States in 2009, with minor spec differences.
Production
Production Period:
2008-2012 (XR1200), XR1200X variant available shortly after.
Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Received positive reviews for its handling and performance, often praised for deviating from traditional Harley-Davidson cruiser characteristics.
Certifications
Emissions Compliance:
Compliant with emissions standards for its respective market at the time of manufacture (details in manual).