This manual covers the 2010 XL1200R, a celebrated cruiser motorcycle from the iconic Sportster lineage. Known for its powerful Evolution V-Twin engine and classic styling, the XL1200R offers a distinct riding experience. This model, manufactured in the United States, builds upon a rich heritage that began with the Sportster line in 1957, representing a modern interpretation with electronic fuel injection and a focus on performance. Its robust engineering and reliability are hallmarks of the brand, making it a popular choice for riders seeking both style and substance. This comprehensive factory service repair manual provides detailed information essential for the maintenance, diagnosis, and repair of your 2010 XL1200R. It includes extensive coverage of all major systems, including the engine, transmission, electrical components, and chassis. Within its hundreds of pages, you will find step-by-step procedures for routine maintenance, troubleshooting common issues, component disassembly and reassembly, and technical specifications such as torque values and clearances. This manual is an indispensable resource for owners, independent repair shops, and DIY enthusiasts aiming to keep their XL1200R in optimal condition. 🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200R Year: 2010 Platform: Sportster Codes Chassis Code: XL 👋 Introduction Market Position Market Segment: Cruiser Motorcycle Target Audience: Harley-Davidson Owners, Independent Repair Shops, DIY Enthusiasts Competitive Analysis Manual Advantage: Provides Official Factory Data, Superior to Generic Aftermarket Guides Key Features Key Benefit: Enables Comprehensive DIY Maintenance and Repair for the XL1200R Documentation Type: Factory Service Manual 📋 Manual Details Coverage Areas Coverage Type: Complete Factory Service Repair Manual Page Count Estimated Pages: Hundreds Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete Engine Assembly, Internal Components, Ignition, Fuel System, Lubrication, Cooling (Air) Transmission: Gearbox Assembly, Clutch, Shifting Mechanism, Final Drive Electrical: Wiring Diagrams, Lighting, Ignition System, Charging System, Starter, Instrumentation, Sensors, ECM/ECU Chassis: Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Exhaust System Bodywork: Body Panels, Fenders, Fuel Tank, Seat, Handlebars, Controls, Fairings (if applicable) Procedures Included Maintenance: Routine Service, Scheduled Maintenance, Lubrication Points, Fluid Changes, Filter Replacements Troubleshooting: Diagnostic Procedures, Symptom-Based Troubleshooting, Fault Code Interpretation Repair: Component Disassembly, Reassembly, Adjustment, Calibration, Replacement Overhaul: Engine Rebuild, Transmission Overhaul, Component Restoration Specifications: Torque Values, Clearances, Tolerances, Electrical Specifications Technical Depth Depth: Comprehensive Factory Level Detail Diagnostic Capability: Advanced Diagnostic Procedures for All Major Systems Rebuild Instructions: Detailed Step-by-Step Rebuild Procedures for Engine, Transmission, and Major Components 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Fully Printable, Allows for Sectional or Full Document Printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Text Search: Searchable Text Content ⚙️ Engine Specifications Primary Engine Engine Type: Evolution V-Twin (Air-Cooled) Displacement: 73.4 cu in (1202 cc) Bore X Stroke: 3.500 in x 3.812 in (88.9 mm x 96.8 mm) Compression Ratio: 9.7:1 Performance Horsepower Estimated: Approx. 65-70 HP (Varies with exhaust/tuning) Torque Estimated: Approx. 70-75 lb-ft @ 3500 RPM (Varies with exhaust/tuning) Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) Fuel Type: Unleaded Gasoline, Minimum 91 Octane (AKI) Ignition Ignition System: Electronic Ignition with Knock Control Lubrication Oil Type: Harley-Davidson Syn3 (or equivalent SAE 20W50 motorcycle oil) Oil Capacity W Filter: 3.0 US qt (2.8 L) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Constant Mesh Optional Optional Transmission: N/A Features Clutch Type: Wet, Multi-plate Final Drive: Belt Drive Transmission Fluid Type: Harley-Davidson Manual Transmission Lubricant (or equivalent SAE 80W-90 GL-5) 📐 Dimensions Exterior Length: 88.4 in (2245 mm) Width: 34.5 in (876 mm) Height: 47.2 in (1199 mm) Wheelbase: 60.2 in (1530 mm) Weights Dry Weight: 573 lbs (260 kg) Gross Vehicle Weight Rating: 937 lbs (425 kg) Cargo Fuel Capacity: 4.5 US gal (17 L) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle, Not Applicable) Active Features Braking System: Dual Disc Front Brakes, Single Disc Rear Brake ABS: Optional (Check Specific Build) Passive Features Lighting: Halogen Headlight, LED Tail/Stop Light, Amber Turn Signals 💡 Technology Features Infotainment Infotainment System: Basic Instrumentation (Speedometer, Tachometer, Odometer, Trip Meter, Fuel Gauge) Audio System: N/A (Typically aftermarket upgrade) Driver Assistance Cruise Control: N/A (Not factory standard on this model) Connectivity Connectivity Features: N/A Engine Management ECM: ECM (Electronic Control Module) controlling fuel injection and ignition timing 🔧 Maintenance Service Intervals First Service: 1,000 miles (1600 km) or 6 months Subsequent Service: Every 5,000 miles (8,000 km) or 12 months thereafter Fluid Specifications Primary Fluid: Harley-Davidson Primary Fluid (or equivalent SAE 85W-140) Brake Fluid: DOT 4 Known Issues Common Wear Items: Clutch plates, primary chain tensioner, voltage regulator, wheel bearings, spark plugs Potential Faults 2010: Some early models might exhibit issues with the automatic compression releases (ACRs) on the starter system, though typically addressed via software updates or component replacement. Check for potential exhaust gasket leaks. Filter Part Numbers...