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Harley Davidson Sportster 1200 Low 2009 Service Repair Manua

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster 1200 Low Year: 2009 Generation Model Generation: XL (Evo Sportster) Codes Vin Vehicle Identification Number Decoder Prefix: 1HD 👋 Introduction Market Position Bike Segment: Cruiser, Entry-Level Harley-Davidson Target Audience: New riders, experienced riders seeking a lighter-weight Harley-Davidson, customizers. Competitive Analysis Key Competitors 2009: Indian Chief, Victory Kingpin, Honda Shadow, Yamaha V-Star, Kawasaki Vulcan. Key Features Sportster 1200 Low Distinction: Lower seat height, wider handlebars for a more relaxed riding position compared to standard Sportsters. Manual Purpose: To provide comprehensive, expert-level guidance for the maintenance, repair, and troubleshooting of the 2009 Harley-Davidson Sportster 1200 Low. 📋 Manual Details Coverage Areas Primary Coverage: 2009 Harley-Davidson Sportster 1200 Low (XL1200L) Related Models Covered: May include general Sportster platform information applicable to other XL models of the era. Page Count Estimated Page Count: Approximately 500-700 pages (typical for comprehensive service manuals) Manual Type Manual Classification: Service Repair Workshop Manual Language Language Of Publication: English Format Delivery Format: Digital Download (PDF) - Assumed based on common sales practices for this type of product. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine teardown, assembly, overhaul, troubleshooting, performance tuning, component identification, torque specifications, timing. Fuel System: Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel pressure testing, diagnostic procedures, carburetion (if applicable to specific variants). Ignition System: Ignition module, spark plugs, ignition coils, wiring diagrams, troubleshooting ignition faults. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), wiring harnesses, fuses, relays, diagnostic codes (DTCs). Transmission: Clutch operation, primary drive, transmission gears, shift mechanism, maintenance, troubleshooting, fluid specifications. Drivetrain: Belt drive system, rear sprocket, wheel bearings, troubleshooting drivetrain noise and wear. Brakes: Front and rear brake systems, calipers, master cylinders, brake lines, brake pads, rotor inspection, bleeding procedures, troubleshooting brake performance. Suspension: Front forks (telescopic), rear shock absorbers, fork oil specifications and levels, fork seal replacement, shock absorber adjustments. Frame And Bodywork: Frame inspection, body panel removal and installation, fairings, fenders, seat, fuel tank, handlebars, control cables. Wheels And Tires: Wheel removal and installation, tire inspection and replacement, wheel balancing, spoke tension (if applicable). Diagnostics: Diagnostic Trouble Codes (DTCs), diagnostic tools, troubleshooting charts, common fault diagnosis. Procedures Included Maintenance Procedures: Oil changes, filter replacement, spark plug replacement, chain adjustment, brake pad inspection, tire pressure checks, battery maintenance. Repair Procedures: Complete engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical system troubleshooting and repair. Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting. Disassembly And Assembly: Detailed instructions for the removal and installation of all major components and sub-assemblies. Wiring Diagrams: Comprehensive electrical wiring schematics for all systems. Technical Depth Diagnostic Capabilities: Advanced diagnostics, including interpretation of diagnostic trouble codes (DTCs) and sensor data. Repair Complexity: Suitable for both DIY enthusiasts and professional mechanics, covering everything from basic maintenance to complete engine and transmission overhauls. Special Tools Required: Lists specific Harley-Davidson special tools and their applications where necessary for proper service. 📊 Manual Specifications File Format Digital Format Type: Portable Document Format (PDF) Searchability: Likely text-searchable PDF for quick information retrieval. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding If Printed: N/A (Digital Format) Paper Type Paper Type If Printed: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-twin Displacement: 1200cc (73.2 cubic inches) Bore X Stroke: 3.500 in x 3.812 in (88.9 mm x 96.8 mm) Compression Ratio: 9.7:1 (Typical for this era) Valve Train: Overhead valves (OHV), 2 valves per cylinder Cooling System: Air-cooled Performance Horsepower: Approximately 66-70 HP @ 5500 RPM (Estimated, varies slightly by dyno and conditions) Torque: Approximately 70-73 lb-ft @ 3500 RPM (Estimated) Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI 🔧 Transmission Standard Transmission Type: 5-speed manual, constant mesh Clutch Type: Wet, multi-plate Primary Drive: 1.787:1, 34/19 tooth, double row chain Final Drive: Belt drive, 32/66 tooth, 1.250 in (32 mm) wide belt, 2.0625:1 ratio Features Gear Ratios: 1st: 10.375, 2nd: 7.750, 3rd: 5.500, 4th: 4.172, 5th: 3.307 Transmission Fluid Type: Harley-Davidson Hypoid Gear Oil (Formula+ or equivalent recommended for primary/transmission) 📐 Dimensions Exterior Length: 90.0 in (2286 mm) Width Handlebar: 34.5 in (876 mm) Height: 47.3 in (1201 mm) Seat Height Laden: 25.3 in (643 mm) (Crucial for the 'Low' model) Ground Clearance: 4.3 in (109 mm) Weights Dry Weight: 566 lbs (257 kg) Gross Vehicle Weight Rating Gvwr: 932 lbs (423 kg) Fuel Capacity: 4.5 US gal (17 L) Oil Capacity: 3.0 US qt (2.8 L) (with filter change) 🛡️ Safety Features Ratings Safety Certification: DOT, EPA, CARB Compliant (as required by region) Active Features Braking System: Dual disc front, single disc rear (hydraulic, ABS typically optional or not available on base 2009 models) Lighting: Halogen headlight, LED taillight/brake light,...
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Harley Davidson Sportster 1200 Low 2009 Service Repair Manua
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster 1200 Low
Year:
2009
Generation
Model Generation:
XL (Evo Sportster)
Codes
Vin Vehicle Identification Number Decoder Prefix:
1HD
👋 Introduction
Market Position
Bike Segment:
Cruiser, Entry-Level Harley-Davidson
Target Audience:
New riders, experienced riders seeking a lighter-weight Harley-Davidson, customizers.
Competitive Analysis
Key Competitors 2009:
Indian Chief, Victory Kingpin, Honda Shadow, Yamaha V-Star, Kawasaki Vulcan.
Key Features
Sportster 1200 Low Distinction:
Lower seat height, wider handlebars for a more relaxed riding position compared to standard Sportsters.
Manual Purpose:
To provide comprehensive, expert-level guidance for the maintenance, repair, and troubleshooting of the 2009 Harley-Davidson Sportster 1200 Low.
📋 Manual Details
Coverage Areas
Primary Coverage:
2009 Harley-Davidson Sportster 1200 Low (XL1200L)
Related Models Covered:
May include general Sportster platform information applicable to other XL models of the era.
Page Count
Estimated Page Count:
Approximately 500-700 pages (typical for comprehensive service manuals)
Manual Type
Manual Classification:
Service Repair Workshop Manual
Language
Language Of Publication:
English
Format
Delivery Format:
Digital Download (PDF) - Assumed based on common sales practices for this type of product.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine teardown, assembly, overhaul, troubleshooting, performance tuning, component identification, torque specifications, timing.
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel pressure testing, diagnostic procedures, carburetion (if applicable to specific variants).
Ignition System:
Ignition module, spark plugs, ignition coils, wiring diagrams, troubleshooting ignition faults.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), wiring harnesses, fuses, relays, diagnostic codes (DTCs).
Transmission:
Clutch operation, primary drive, transmission gears, shift mechanism, maintenance, troubleshooting, fluid specifications.
Drivetrain:
Belt drive system, rear sprocket, wheel bearings, troubleshooting drivetrain noise and wear.
Brakes:
Front and rear brake systems, calipers, master cylinders, brake lines, brake pads, rotor inspection, bleeding procedures, troubleshooting brake performance.
Suspension:
Front forks (telescopic), rear shock absorbers, fork oil specifications and levels, fork seal replacement, shock absorber adjustments.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fairings, fenders, seat, fuel tank, handlebars, control cables.
Wheels And Tires:
Wheel removal and installation, tire inspection and replacement, wheel balancing, spoke tension (if applicable).
Diagnostics:
Diagnostic Trouble Codes (DTCs), diagnostic tools, troubleshooting charts, common fault diagnosis.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, chain adjustment, brake pad inspection, tire pressure checks, battery maintenance.
Repair Procedures:
Complete engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical system troubleshooting and repair.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting.
Disassembly And Assembly:
Detailed instructions for the removal and installation of all major components and sub-assemblies.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all systems.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including interpretation of diagnostic trouble codes (DTCs) and sensor data.
Repair Complexity:
Suitable for both DIY enthusiasts and professional mechanics, covering everything from basic maintenance to complete engine and transmission overhauls.
Special Tools Required:
Lists specific Harley-Davidson special tools and their applications where necessary for proper service.
📊 Manual Specifications
File Format
Digital Format Type:
Portable Document Format (PDF)
Searchability:
Likely text-searchable PDF for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding If Printed:
N/A (Digital Format)
Paper Type
Paper Type If Printed:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.500 in x 3.812 in (88.9 mm x 96.8 mm)
Compression Ratio:
9.7:1 (Typical for this era)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Cooling System:
Air-cooled
Performance
Horsepower:
Approximately 66-70 HP @ 5500 RPM (Estimated, varies slightly by dyno and conditions)
Torque:
Approximately 70-73 lb-ft @ 3500 RPM (Estimated)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI
🔧 Transmission
Standard
Transmission Type:
5-speed manual, constant mesh
Clutch Type:
Wet, multi-plate
Primary Drive:
1.787:1, 34/19 tooth, double row chain
Final Drive:
Belt drive, 32/66 tooth, 1.250 in (32 mm) wide belt, 2.0625:1 ratio
Features
Gear Ratios:
1st: 10.375, 2nd: 7.750, 3rd: 5.500, 4th: 4.172, 5th: 3.307
Transmission Fluid Type:
Harley-Davidson Hypoid Gear Oil (Formula+ or equivalent recommended for primary/transmission)
📐 Dimensions
Exterior
Length:
90.0 in (2286 mm)
Width Handlebar:
34.5 in (876 mm)
Height:
47.3 in (1201 mm)
Seat Height Laden:
25.3 in (643 mm) (Crucial for the 'Low' model)
Ground Clearance:
4.3 in (109 mm)
Weights
Dry Weight:
566 lbs (257 kg)
Gross Vehicle Weight Rating Gvwr:
932 lbs (423 kg)
Fuel Capacity:
4.5 US gal (17 L)
Oil Capacity:
3.0 US qt (2.8 L) (with filter change)
🛡️ Safety Features
Ratings
Safety Certification:
DOT, EPA, CARB Compliant (as required by region)
Active Features
Braking System:
Dual disc front, single disc rear (hydraulic, ABS typically optional or not available on base 2009 models)
Lighting:
Halogen headlight, LED taillight/brake light, amber incandescent turn signals.
Passive Features
Frame Construction:
Steel tube, cradle frame.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer (optional or integrated on some models), LCD display for odometer, trip meter, clock, gear indicator, fuel gauge.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was typically an optional feature for 2009 models, not standard on all trims.
Connectivity
Standard Connectivity:
None (No Bluetooth, smartphone integration typical for this era).
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter (refer to manual for specifics)
Belt Tension Check:
Check at 1,000 miles, then every 5,000 miles or annually.
Fluid Specifications
Engine Oil Type:
Harley-Davidson SYN3 (Synthetic) or H-D 20W-50 Motorcycle Oil (or approved equivalent)
Primary Chain Case Oil:
Harley-Davidson Formula+ or approved equivalent
Transmission Oil Type:
Harley-Davidson Hypoid Gear Oil (or approved equivalent)
Fork Oil:
Harley-Davidson Type E or Type B fork oil (specific weight depends on application, consult manual)
Known Issues
Common Sportster Issues 2009:
Primary chain tensioner wear (especially the earlier spring-loaded type, though later models adopted hydraulic tensioners), rear brake pad wear, occasional electrical connector corrosion, fuel sensor issues.
Manual Coverage Of Issues:
The manual will detail diagnostic and repair procedures for these and other potential issues.
📚 Vehicle History
Brand Heritage
Harley Davidson Legacy:
Founded in 1903, iconic American motorcycle manufacturer with a rich history in V-twin engines and cruiser styling.
Model Evolution
Sportster Lineage:
The Sportster platform has been in continuous production since 1957, evolving from ironhead engines to the rubber-mounted Evolution engine (introduced in 1986).
1200 Low Introduction:
The 'Low' variant was introduced to cater to riders seeking a more accessible and comfortable riding experience, characterized by its lower seat height and revised ergonomics.
Production
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin)
🏆 Awards & Recognition
Recognitions
Sportster Model Awards:
Sportster models often receive accolades in enthusiast publications for their classic styling, V-twin character, and customization potential. Specific awards for the 2009 1200 Low may vary.
Ratings
Consumer Reports Ratings:
Consumer Reports or similar publications may have rated specific aspects of the 2009 Sportster line, often focusing on reliability (which can be variable for Harley-Davidson models of this period).
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