Harley Davidson XL1200C Sportster 2008 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Year: 2008 Generation Sportster Generation: Evolution Engine Era Codes Vin Prefix: 1HD 👋 Introduction Market Position Segment: Cruiser Motorcycle Target...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 494751

Stichworte: 2008 Harley Davidson Misc Motorcycle Motorcycles XL1200C Sportster

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

Generation

Sportster Generation:

Evolution Engine Era

Codes

Vin Prefix:

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson owners seeking to perform their own maintenance, repairs, and modifications.

Competitive Analysis

Differentiation:

Provides the same level of detail and accuracy found in official Harley-Davidson service literature, covering all aspects of the XL1200C for 2008.

Key Features

Content Value:

Invaluable resource for reducing maintenance costs and ensuring the longevity and optimal performance of the motorcycle.

Diagnostic Capabilities:

Empowers owners to diagnose and repair issues independently, saving time and money on dealership visits.

📋 Manual Details

Coverage Areas

Engine Overhaul:

Comprehensive

Electrical System Diagnostics:

Comprehensive

Chassis And Suspension Repair:

Comprehensive

Fuel And Ignition System:

Comprehensive

Brake System Maintenance:

Comprehensive

Bodywork And Cosmetics:

Comprehensive

Troubleshooting And Diagnostics:

Extensive

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, and tuning of the Evolution V-Twin engine.

Fuel System:

Carburetor (Keihin CV type) maintenance, adjustment, and overhaul; fuel pump and filter service.

Ignition System:

Ignition module, spark plugs, ignition coils, and timing system diagnostics and service.

Transmission And Drivetrain:

5-speed transmission service, clutch operation, belt drive system inspection and adjustment.

Suspension:

Front fork overhaul, rear shock absorber service, and suspension tuning.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, hydraulic system bleeding, and pad replacement.

Electrical:

Wiring diagrams, lighting system, battery charging system (alternator, regulator), starter motor, and accessory circuits.

Frame And Body:

Frame inspection, fender and tank removal/installation, seat service, and exhaust system maintenance.

Wheels And Tires:

Wheel bearing service, tire inspection and replacement, and spoke maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication, chain/belt adjustment, brake checks.

Component Rebuild:

Engine top-end and bottom-end rebuilds, transmission rebuilds, carburetor overhaul.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common and complex issues, including electrical faults.

Special Tools:

Identification and usage of specialized Harley-Davidson tools required for specific repairs.

Torqure Specifications:

Precise torque values for all critical fasteners across all systems.

Wiring Diagrams:

Detailed, high-resolution electrical schematics for accurate diagnosis.

Performance Tuning:

Information on carburetor adjustments and ignition timing for optimal performance.

Technical Depth

Depth:

Comprehensive, covering everything from basic user maintenance to full engine rebuilds and advanced electrical diagnostics.

📊 Manual Specifications

File Format

Type:

PDF (Portable Document Format)

Searchability:

Fully searchable text for quick information retrieval.

Resolution:

High-resolution images and diagrams for clarity.

Print Quality

Printability:

Printable, allowing for physical copy creation.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Valve Train:

Overhead valves (OHV) with pushrods, 2 valves per cylinder

Cylinder Heads:

Aluminum alloy

Cooling System:

Air-cooled

Performance

Horsepower Approx:

65-70 HP (at crankshaft, estimated)

Torque Approx:

70-75 lb-ft (at crankshaft, estimated)

Fuel System

Fuel Delivery:

Carburetor (Keihin CV 40mm)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

4.0 US gallons (15.1 L)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Primary Drive:

Duplex chain, 26/57 ratio

Final Drive:

Belt drive, 32/65 ratio

Features

Clutch Type:

Wet, multi-plate

Transmission Fluid Type:

Harley-Davidson Formula+ or equivalent API GL-4, SAE 80W90 gear oil

📐 Dimensions

Exterior

Length:

92.5 in (2350 mm)

Width:

35.6 in (904 mm)

Height:

49.0 in (1245 mm)

Wheelbase:

60.2 in (1530 mm)

Ground Clearance:

4.2 in (107 mm)

Weights

Dry Weight:

575 lbs (261 kg)

Gross Vehicle Weight Rating:

970 lbs (440 kg)

Front Tire Size:

100/90-19 57H

Rear Tire Size:

150/80B16 71H

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 in)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not subjected to standardized crash testing like automobiles. Safety is inherent in design and rider responsibility.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Headlight, taillight, brake light, turn signals, and auxiliary lighting as standard.

Passive Features

Frame Construction:

Steel cradle frame designed for stability and rider control.

Ergonomics:

Forward-mounted foot controls and a comfortable rider triangle designed for extended riding.

💡 Technology Features

Infotainment

System:

Basic, focused on analogue gauges (speedometer, tachometer optional) and essential indicator lights.

Driver Assistance

Features:

No electronic driver assistance systems as per the era and model's focus on classic motorcycle riding experience.

Connectivity

Features:

No onboard connectivity features.

🔧 Maintenance

Service Intervals

First Service:

1000 miles (1600 km) or 6 months

Subsequent Services:

Every 5000 miles (8000 km) or 12 months thereafter

Belt Tension Check:

Every 5000 miles (8000 km)

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 (Synthetic) or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson specifications.

Engine Oil Capacity:

3.0 US quarts (2.8 L) with filter change

Primary Chain Case Fluid Type:

Harley-Davidson Formula+ or equivalent API GL-4, SAE 80W90 gear oil.

Primary Chain Case Fluid Capacity:

2.5 US quarts (2.4 L)

Brake Fluid Type:

DOT 4 Hydraulic Fluid

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, belt drive components.

Electrical Quirks:

Occasionally, older models can exhibit issues with starter solenoids, voltage regulators, or wiring connections due to age and vibration.

Engine Performance Tuning:

Carburetor tuning can be critical for optimal performance, especially with modifications or altitude changes.

📚 Vehicle History

Brand Heritage

Legacy:

Harley-Davidson boasts a rich history dating back to 1903, synonymous with American motorcycling culture and freedom.

Model Evolution

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running and most iconic models, evolving significantly over the decades.

Xl1200C Custom:

The XL1200C Custom variant emphasizes a classic custom look with features like a larger displacement engine, chrome accents, and a lower seat height, becoming a popular model for personalization.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA

Model Year Significance:

The 2008 model year saw continued refinement of the Evolution engine and chassis, representing a mature and well-established platform.

🏆 Awards & Recognition

Recognitions

Model Status:

The Sportster line is consistently recognized as a benchmark in the cruiser segment for its style, performance, and customization potential.

Ratings

Reliability Perception:

Generally considered reliable with proper maintenance. The Evolution engine is a robust and proven design.

Certifications

Manual Compliance:

This manual is designed to align with industry-standard repair practices and specifications for Harley-Davidson motorcycles.