When I first laid eyes on the 2009 Harley Davidson XR1200, I was hooked. It looked different—like Harley had finally built a bike that wasn’t just for cruising. It had real attitude. It promised performance, sportier handling, and something a little closer to a café racer vibe, all while keeping that Harley rumble. But as cool as the XR1200 is, it’s not perfect. If you’re thinking about picking one up, there are some quirks and issues you should be ready for. Here’s what I’ve learned from riding and wrenching on this bike—and what others who’ve owned one have shared.
The Oil Tank Problem (Yes, It Can Crack)
Let’s start with one of the biggest known issues: the oil tank.
On many 2009 XR1200s, the rear mounting tab of the oil tank has a nasty habit of cracking. What makes it worse is that it can start leaking oil. Not only does that make a mess, but it can also be a fire hazard if the oil gets near hot components like the exhaust.
The reason? The tank is mounted directly to the frame with little-to-no vibration isolation. So when you ride—especially hard—the constant shaking eventually fatigues the mount. Harley seemed to know this too. In 2010 and later, they changed the oil tank design and added rubber grommets to soften the connection.
How to Fix It:
- Some riders use aftermarket rubber grommets or washers to add isolation.
- Others have tried modifying the bracket to spread the stress.
- Worst case, you’ll need a new tank—which isn’t cheap.
Bottom line? If you’re looking at a 2009 model, check the oil tank mount closely. Better yet, see if it’s already been updated.
You can also see: Harley Davidson 1200 Sportster Common Problems: The Ultimate Guides
Rear Brake Troubles: Weak Feel and Uneven Wear
The rear brake on the 2009 XR1200 is another common complaint—and I’ve felt this myself. It’s just… weak. Even when it’s working right, the pedal feel is vague, and stopping power is underwhelming. But for some riders, it’s more than just a soft pedal.
A few owners have noticed uneven pad wear or a rear brake that locks up too easily under pressure. One possible reason? The rear master cylinder and caliper setup isn’t the best match for the bike’s weight and intended performance. Also, some bikes seem more prone to air in the brake lines, which only makes the spongy feeling worse.
What You Can Do:
- Bleed the brakes thoroughly to remove any air in the lines.
- Upgrade to higher-quality brake pads (like EBC HH-rated ones).
- Check for rotor warping or caliper alignment if you’re seeing uneven wear.
Some folks have swapped out the rear master cylinder for a better-performing one. That’s more work, but if you rely on the rear brake in traffic or on twisty roads, it might be worth it.
Electrical Gremlins and Charging Issues
This one caught me off guard the first time it happened. One day, I turned the key—and nothing. Dead bike. Turns out, electrical issues are another problem area on the 2009 Harley Davidson XR1200.
Some riders have reported parasitic battery drain. You park your bike with a full charge, come back a few days later, and the battery’s flat. The culprit is usually a weak voltage regulator or a bad ground connection. Others have seen the charging system fail altogether, especially after the bike warms up.
Common Signs to Watch:
- Bike won’t start after sitting for a few days
- Headlights flicker or dim while riding
- Battery needs frequent charging
- Sudden stalling with no warning
Fixes and Tips:
- Replace the stock voltage regulator with a more reliable aftermarket one.
- Clean all ground connections and check for corrosion on terminals.
- Use a multimeter to test your charging system—voltage should read around 14V when running.
This isn’t unique to the XR1200, but it seems more frequent on early models like the 2009. Some riders also add a battery tender lead and keep their bikes on a trickle charger to avoid being stranded.
Suspension and Handling Concerns
Now, let’s talk about the handling. The 2009 Harley-Davidson XR1200 was designed with a unique mix of sport and cruiser characteristics, and while it shines in many areas, its suspension can be a bit hit-or-miss.
A common issue some riders report is a somewhat stiff, uncomfortable ride, especially on rough roads. The front suspension in particular has been a point of contention. Some feel the forks are too firm, especially when compared to the plush ride you might expect from a typical cruiser.
For the rear suspension, there have been reports of it being too soft for aggressive riding. The bike can feel a bit squishy when leaning into turns, and you may notice it bottoming out if you take it over bumps or potholes at speed. This can be a little unnerving if you’re used to a bike that handles well under stress.
What to Look For:
- Harsh or uncomfortable ride over uneven terrain
- Bottoming out on bumps or hard turns
- Unstable or twitchy handling during aggressive cornering
Solutions:
- Swap out the stock suspension for adjustable, aftermarket components (such as from Ohlins or Progressive Suspension) to dial in your preferred ride quality.
- Check if the fork oil has been replaced or needs refreshing—old oil can lead to poor damping and a harsh ride.
- Consider adjusting the rear shocks to the firmest setting if you’re carrying heavier loads or pushing the bike through tighter corners.
Upgrading suspension components is a solid investment if you’re looking for a smoother, more controlled ride, especially for those who use their XR1200 as a performance bike rather than a weekend cruiser.
You can also see: Why I Switched to the Best Oil for Harleys 2025
Electrical Issues
Let’s talk about electrical problems. These can affect older Harley-Davidson bikes, including the 2009 XR1200. If your bike is getting on in years, you might run into some of these issues.
Common Electrical Problems:
- Battery Drain: Some riders say the XR1200’s battery doesn’t last long. This can happen if the charging system, like the regulator or stator, isn’t working right. If the bike is hard to start, or the battery runs out quickly, that’s a sign.
- Loose Wiring: Another issue some owners face is loose wiring. Vibration can loosen wires or cause connections to fail. This can lead to lights flickering or even power loss while riding.
- Blown Fuses: Fuses can blow from time to time. It’s a simple fix, but if it happens often, it could mean a bigger electrical issue.
What to Look For:
- A dead battery or trouble starting
- Flickering lights or sudden power loss
- Blown fuses
Solutions:
- Check the battery for corrosion. If it’s old, you may need to replace it. If the problem continues, have the charging system tested.
- Inspect the wiring. Look for loose or damaged connections, especially around the engine.
- If fuses keep blowing, check for short circuits or other electrical problems.
Key XR1200-Specific Maintenance Checks & Common Issues
| Area/Component | Check/Action | Frequency | Potential Issue if Neglected |
| Fasteners/Finish | Inspect for Corrosion/Damage; Apply Protectant | Regularly / After Washing | Seized/Broken Bolts, Component Failure |
| Electrical Connections (Fuse Box) | Inspect for Corrosion; Clean & Apply Dielectric Grease | Annually / Major Service | Poor Connection, Intermittent/Total Failure |
| Drive Belt | Inspect for Cuts/Stone Damage | Pre-Ride / Service Interval | Sudden Belt Failure |
| Wheel Axles/Bearings | Check for Corrosion/Smooth Operation; Apply Anti-Seize | Wheel Removal / Service Interval | Difficult Wheel Removal, Bearing Failure |
| Oil Cooler / Shift Linkage | Inspect for Damage/Security | Pre-Ride / After Any Drop | Oil Leak / Shift Failure |
| Fuel Level Sensor | Monitor Low Fuel Light Behavior vs. Mileage | Ongoing | Running Out of Fuel Unexpectedly |
| Starter Relay/Solenoid | Listen for Abnormal Starter Operation | Ongoing | No Start Condition |
FAQs
1: What are common problems with the 2009 Harley Davidson XR1200?
The 2009 Harley Davidson XR1200 may have issues with engine knocking, suspension setup, and electrical systems. Regular maintenance can help reduce these problems and extend the bike’s life.
2: How can I fix engine knocking on the 2009 Harley Davidson XR1200?
Engine knocking in the 2009 Harley Davidson XR1200 can be caused by improper fuel or low oil levels. Try using high-quality fuel and keep the engine oil topped up to reduce knocking sounds.
3: Why does my 2009 Harley Davidson XR1200 have suspension problems?
The 2009 XR1200 may have suspension issues due to worn-out shocks or improper adjustment. Check the shock absorbers regularly and adjust or replace them as needed for a smoother ride.
4: What electrical problems should I look out for on the 2009 Harley Davidson XR1200?
Electrical problems on the 2009 XR1200 can include battery drain, loose wiring, and blown fuses. Regular checks on the battery and wiring connections can help prevent these issues.
5: How do I maintain the 2009 Harley Davidson XR1200 to avoid common problems?
To avoid common problems with your 2009 Harley Davidson XR1200, perform regular maintenance such as checking oil levels, inspecting the suspension, and testing the battery and wiring connections.
6: Can the suspension on the 2009 Harley Davidson XR1200 be upgraded?
Yes, the suspension on the 2009 Harley Davidson XR1200 can be upgraded for better performance. Consider aftermarket suspension options for improved comfort and handling, especially if you ride on various terrains.
7: How can I tell if the battery is the problem with my 2009 Harley Davidson XR1200?
If your 2009 Harley Davidson XR1200 struggles to start or the lights flicker, the battery might be the issue. Check the battery for corrosion, and if it’s old, consider replacing it.
8: What should I do if my 2009 Harley Davidson XR1200’s lights are flickering?
Flickering lights on your 2009 Harley Davidson XR1200 could be a sign of loose wiring or a failing charging system. Inspect the wiring and charging system to identify and fix the issue.
9: Are there any known issues with the tires on the 2009 Harley Davidson XR1200?
Some riders have reported tire wear issues on the 2009 Harley Davidson XR1200. Ensure your tires are properly inflated and check for any signs of damage to improve safety and handling.
10: How often should I service my 2009 Harley Davidson XR1200?
It’s recommended to service your 2009 Harley Davidson XR1200 every 5,000 miles or as specified in the owner’s manual. Regular service can prevent major problems and keep your bike running smoothly.
Final Thoughts
The 2009 Harley-Davidson XR1200 is a great bike, but it has a few common problems. These include engine knocking, suspension issues, and electrical troubles. With proper care, you can keep these problems in check.
Many riders still love the XR1200 for its style and performance. The key is regular maintenance. Stay on top of repairs and keep an eye out for signs of wear. If you’re buying one, check for these issues. If you own one, stay proactive about fixing problems.
With the right care, your XR1200 can keep running smoothly for years.
