🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2008

Platform:

Evolution Engine Sportster

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson owners seeking to perform their own maintenance and repairs, DIY enthusiasts

Advantage:

Provides expert guidance for a specific model, enabling owners to save on dealership labor costs and ensure quality of work.

Diy Focus:

Empowers owners to take control of their vehicle's maintenance and repair

Comprehensiveness:

Covers a wide range of repair and maintenance procedures for all major vehicle systems

📋 Manual Details

Full Service Repair:

All systems and components

Estimated Pages:

Hundreds (typical for comprehensive service manuals, exact count not provided in source)

Type:

Service and Repair Manual

Language:

English

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine:

Evolution V-Twin (1200cc), including disassembly, assembly, tuning, and troubleshooting

Fuel System:

Fuel injection (EFI) system, components, diagnostics, and adjustments

Ignition System:

Electronic ignition, spark plugs, coils, and related components

Transmission:

5-speed constant mesh transmission, clutch, primary drive, and final drive

Electrical System:

Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, and accessories

Braking System:

Front and rear hydraulic disc brakes, master cylinders, calipers, and fluid specifications

Suspension:

Front fork (telescopic) and rear shock absorber systems, including adjustments and overhaul

Frame And Bodywork:

Frame inspection, body panel removal/installation, seat, fenders, and tanks

Wheels And Tires:

Wheel bearing maintenance, tire pressure, and replacement procedures

Exhaust System:

Exhaust components, gaskets, and mounting hardware

Cooling System:

Air-cooled engine management, oil cooler (if applicable to specific sub-models)

Routine Maintenance:

Oil changes, filter replacements, spark plug inspection/replacement, chain/belt adjustments, lubrication

Troubleshooting:

Diagnostic charts, common problems, and step-by-step solutions for various systems

Engine Overhaul:

Detailed procedures for engine disassembly, component inspection, reassembly, and break-in

Transmission Repair:

Clutch adjustment, primary drive inspection, transmission disassembly and reassembly

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, testing procedures for components

Brake System Maintenance:

Brake fluid bleeding, pad replacement, caliper service, and master cylinder replacement

Suspension Service:

Fork seal replacement, fork oil changes, rear shock absorber service

Fuel System Cleaning:

Injector cleaning, fuel filter replacement, fuel line inspection

Performance Tuning:

Basic adjustments for EFI and ignition timing (where applicable and user-adjustable)

Depth:

Comprehensive from basic maintenance to advanced internal component repair and diagnostics

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable for efficient information retrieval

Quality:

Designed for clarity with diagrams and text, suitable for printing

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200cc (73.3 cu. in.)

Bore X Stroke:

3.496 in. x 4.000 in. (88.8 mm x 101.6 mm)

Compression Ratio:

9.0:1

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Horsepower:

Approximately 67 hp @ 5500 rpm (Manufacturer estimate, actual may vary)

Torque:

Approximately 70 ft-lbs @ 3500 rpm (Manufacturer estimate, actual may vary)

Fuel Type:

Unleaded gasoline, minimum 91 octane (R+M)/2

🔧 Transmission

Type:

5-speed, constant mesh

Primary Drive:

Clutch, chain drive to transmission

Final Drive:

Belt drive

Clutch Type:

Multi-plate, wet

Transmission Fluid Type:

Harley-Davidson SYN3 or equivalent (refer to manual for specific grade)

Primary Chain Tensioner:

Automatic hydraulic tensioner (check for wear/operation)

📐 Dimensions

Length:

90.9 in. (2309 mm)

Width:

37.4 in. (950 mm)

Height:

52.0 in. (1320 mm)

Seat Height Laden:

25.5 in. (648 mm)

Ground Clearance:

4.4 in. (112 mm)

Dry Weight:

571 lbs (259 kg)

Gross Vehicle Weight Rating Gvwr:

Not explicitly stated, but typically around 950-1000 lbs for this model class.

Fuel Capacity:

4.5 gal. (17 L)

🛡️ Safety Features

Crash Test Data:

Motorcycles are not typically subjected to standardized crash testing like automobiles.

Brakes:

Dual front disc brakes, Single rear disc brake

Lighting:

Halogen headlight, LED tail light, integrated front and rear turn signals

Frame Construction:

Steel frame and swingarm

💡 Technology Features

System:

Basic instrumentation: speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights.

Features:

No electronic driver assistance features typical of modern cars.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 6 months

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months thereafter

Engine Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first

Transmission Oil Change:

Every 10,000 miles (16,000 km) or 24 months

Primary Chain Case Oil Change:

Every 10,000 miles (16,000 km) or 24 months

Engine Oil Type:

Harley-Davidson SYN3 (SAE 20W-50) or equivalent V-twin specific motorcycle oil

Engine Oil Capacity:

3.0 US qt. (2.8 L) with filter change

Transmission Fluid Type:

Harley-Davidson Formula+ or equivalent

Transmission Fluid Capacity:

1 US qt. (0.95 L)

Primary Chain Case Fluid Type:

Harley-Davidson Formula+ or equivalent

Primary Chain Case Fluid Capacity:

1 US qt. (0.95 L)

Brake Fluid Type:

DOT 4 hydraulic fluid

Primary Chain Tensioner:

Early models (pre-2007) had a less robust tensioner; 2008 models typically have the improved hydraulic unit. Regular inspection for wear is advised.

Fuel System Efi:

EFI systems can be sensitive to fuel quality and may require occasional cleaning of fuel injectors.

Rear Belt Drive:

Requires proper tensioning and inspection for cracks or damage. Belt replacement interval is typically longer than chain, but proper alignment is crucial.

📚 Vehicle History

Heritage:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines and distinctive styling.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of the longest-running motorcycle models in continuous production, evolving through various engine displacements and styles, including the XL1200C Custom which emphasizes classic styling with modern features.

Manufacturing Location:

United States (Wisconsin)

🏆 Awards & Recognition

Model Specific:

While the 2008 XL1200C itself may not have specific individual awards, the Sportster line is consistently praised for its styling, customization potential, and authentic Harley-Davidson experience.