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Harley-Davidson · Harley-Davidson Evolution Sportster (1986-2021)

XR1200

Library entry covers 2009-2012

37 factory 42 guideline

Published source

Harley-Davidson 2009 XR1200 Owner's Manual, Regular Service Intervals: 2009 Sportster Models (manuals.plus PDF)

Factory source. Covers Harley-Davidson 2009 Sportster owner's manual (footer prints 2009 XR1200 Owner's Manual).

79 items for a 2010 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Hydraulic lifters (no routine clearance adjustment)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2010 Harley-Davidson XR1200

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

7 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 5,000 mi or 12 months

6 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Engine oil and filter (replace; note 3)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi, or annually. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Exhaust system (inspect for leaks, cracks, loose or missing fasteners or heat shields; note 3)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi, or annually. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Replace oil filter

Engine

Guideline
Inspect drive belt, pulleys and tension

Final drive

Guideline
Oil lines and brake system (inspect for leaks; notes 1, 3)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi, or annually. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 5,000 mi

19 items

Electrical equipment and switches (check operation)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Engine idle speed (check adjustment; note 1)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Rear belt and sprockets (inspect, adjust belt; note 1)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Rear master cylinder outer boot (inspect; notes 1, 2)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every 5,000 mi from 5,000 to 25,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Road test (verify component and system functions)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Spark plugs (inspect)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000, 5,000, 15,000 and 25,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Air cleaner (inspect, service as required)

Fuel and air

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Fuel lines and fittings (inspect for leaks; note 1)

Fuel and air

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Clutch (check adjustment; note 1)

Primary and gearbox

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Primary chain (check adjustment)

Final drive

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Jiffy stand (inspect, lubricate; note 1)

Rear suspension and frame

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Shock absorbers (inspect; note 1)

Rear suspension and frame

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake caliper boots and bushings (inspect; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every 5,000 mi from 5,000 to 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake caliper pins (inspect; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every 5,000 mi from 5,000 to 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake fluid (check level and condition; note 5)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake pads and discs (inspect for wear)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Front brake lever pin (inspect; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every 5,000 mi from 5,000 to 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Throttle, brake and clutch controls (check, adjust, lubricate; note 1)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Tires (check pressure, inspect tread)

Wheels and tires

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 mi, then every 5,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 6,000 mi or 12 months

6 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi

3 items

Critical fasteners (check tightness; note 1)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000, 10,000 and 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Engine mounts and stabilizer links (inspect; note 1)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 10,000 and 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Transmission lubricant (replace)

Primary and gearbox

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000, 10,000 and 20,000 mi, so every 10,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 12,000 mi or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 20,000 mi

3 items

Spark plugs (replace)

Engine

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Steering head bearings (adjust; notes 1, 7)

Front end

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000 and 20,000 mi; disassemble, lubricate and inspect every 30,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Wheel spokes, if fitted (check tightness; notes 1, 4)

Wheels and tires

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 1,000, 5,000 and 20,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 4 years

4 items

Brake caliper boots and bushings (replace; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 25,000 mi, or every four years. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake caliper pins (lubricate; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 25,000 mi, or every four years. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Brake rubber components in master cylinders and calipers (replace); master cylinder pistons (lubricate; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 25,000 mi, or every four years. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Front brake lever pin (lubricate; notes 1, 2)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 25,000 mi, or every four years. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi

1 item

Fuel tank filter screen (replace; note 1)

Fuel and air

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): at 25,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,000 mi

1 item

Rear fork bearings (inspect; note 1)

Front end

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every 30,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 50,000 mi

2 items

Replace drive belt (wear or damage based)

Final drive

Guideline
Front fork oil (replace; notes 1, 6)

Front end

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): disassemble, lubricate and inspect every 50,000 mi. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Battery (check, clean connections; note 3)

Ignition and electrics

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): annually. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake fluid (replace DOT 4 and flush; note 5)

Brakes

Factory

Factory: Regular Service Intervals: 2009 Sportster Models (Harley-Davidson 2009 Sportster owner's manual; page footer prints 2009 XR1200 Owner's Manual and the model list includes the XR 1200; manuals.plus PDF pp.140-141): every two years. Columns as printed: 1,000 mi (1,600 km); 5,000; 10,000; 15,000; 20,000; 25,000 mi. Notes: 1 dealer unless you have the tools, data and skills; 2 replace every four years; 3 perform annually or at the specified interval, whichever first; 4 spoke wheels only; 5 replace DOT 4 brake fluid and flush every two years; 6 disassemble, lubricate and inspect every 50,000 mi; 7 disassemble, lubricate and inspect every 30,000 mi.
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.