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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).
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Harley Davidson XR1200 2009 Workshop Service Repair Manual
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).
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