🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL 1200C Sportster 1200 Custom

Year:

2008

Model Code:

XL1200C

👋 Introduction

Market Segment:

Cruiser motorcycle, specifically a custom variant of the Sportster line.

Target Audience:

Owners of the 2008 Harley-Davidson XL 1200C Sportster 1200 Custom seeking to perform maintenance, repairs, and modifications.

Competitive Set:

Other custom cruisers in its class from American and Japanese manufacturers, although Harley-Davidson occupies a distinct niche.

Vehicle Design Philosophy:

Classic cruiser styling with modern performance, customization potential, and iconic Harley-Davidson V-twin character.

Manual Value Proposition:

Provides authoritative, manufacturer-level repair and maintenance information, empowering owners to maintain their investment and perform necessary work accurately and efficiently.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Fuel System, Ignition System, Exhaust System, Cooling System (if applicable), Bodywork, Frame, Wheels, Tires, Diagnostic Procedures, Troubleshooting, Maintenance Schedules.

Estimated Page Count:

600-800

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Systems:

Evolution V-Twin engine, cylinder head assembly, piston and connecting rod, crankshaft, camshaft, valve train, oil pump, lubrication system, intake system, fuel injection system (EFI), exhaust system.

Drivetrain Systems:

Clutch assembly, primary drive, transmission (5-speed), final drive belt, drive sprocket, rear pulley.

Chassis Systems:

Frame, front fork (telescopic), rear shock absorbers, swingarm, steering assembly, wheel bearing replacement.

Braking Systems:

Front brake caliper, rotor, master cylinder, brake lines. Rear brake caliper, rotor, master cylinder, brake lines. Brake fluid specifications and bleeding procedures.

Electrical Systems:

Battery, charging system (alternator/stator, regulator/rectifier), ignition system (ignition module, spark plugs, coils), starting system (starter motor, solenoid), lighting system (headlight, tail light, turn signals, brake light), instrumentation, wiring diagrams, fuses, relays, horn.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, idle air control (IAC) system.

Suspension Systems:

Front fork internal inspection, seal replacement, oil specification and level; rear shock absorber removal, inspection, and replacement.

Wheel And Tire Systems:

Wheel bearing maintenance and replacement, tire mounting and balancing specifications, recommended tire pressures.

Maintenance Procedures:

Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, belt inspection and tensioning, brake pad replacement, tire pressure checks, chain lubrication (if applicable to specific sub-models or earlier versions, though 2008 XL1200C is belt drive), fluid level checks, battery maintenance.

Repair Procedures:

Engine disassembly and reassembly, transmission overhaul, clutch replacement, fork seal replacement, shock absorber replacement, brake caliper rebuild, starter motor replacement, charging system diagnosis and repair, fuel system troubleshooting and component replacement, wiring harness repair.

Diagnostic Procedures:

Troubleshooting common symptoms, using diagnostic tools (e.g., Harley-Davidson Digital Technician), interpreting error codes, electrical circuit testing.

Bodywork Procedures:

Fender removal/installation, fuel tank removal/installation, seat removal/installation, handlebar replacement, minor body panel repair/adjustment.

Technical Depth:

Comprehensive: Covers everything from routine maintenance and basic adjustments to complete engine and transmission rebuilds, electrical system diagnostics, and frame/suspension repair. Includes detailed torque specifications, tolerances, and assembly instructions.

Torque Specifications:

Detailed torque values for all critical fasteners, engine components, chassis fasteners, and brake system components.

Clearances And Tolerances:

Specific machining clearances and operating tolerances for engine components such as piston-to-cylinder wall, valve stem to guide, and bearing clearances.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (typical for professionally produced PDFs)

Image Quality:

High (designed for clear display of graphics and diagrams)

Binding Type:

N/A (PDF format)

Paper Type:

N/A (PDF format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1202 cc (73.3 cubic inches)

Bore X Stroke:

3.437 in. x 3.976 in. (87.4 mm x 100.6 mm)

Compression Ratio:

9.7:1

Horsepower Peak:

Approx. 67 hp @ 5200 rpm (Estimated for 2008 model)

Torque Peak:

Approx. 70 ft-lbs @ 3500 rpm (Estimated for 2008 model)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

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

Ignition Type:

Electronic, spark ignition

Exhaust Configuration:

Dual exhaust, typically with mufflers and catalytic converter (market dependent)

Oil Type:

Harley-Davidson SYN3 (Synthetic) SAE 20W50 or similar V-Twin specific motorcycle oil.

Engine Oil Capacity:

Approx. 3.0 US quarts (2.8 L) with filter change.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Optional Transmission:

N/A for this model year

Clutch Type:

Wet, multi-plate

Primary Drive:

Chain, 1.36:1 ratio

Final Drive:

Belt drive, 2.75:1 ratio

Transmission Oil Capacity:

Approx. 0.9 US quarts (0.85 L) of Harley-Davidson Formula + or equivalent.

📐 Dimensions

Length:

Approx. 90.5 in. (2299 mm)

Width:

Approx. 33.5 in. (851 mm)

Height:

Approx. 45.7 in. (1161 mm)

Wheelbase:

Approx. 60.0 in. (1524 mm)

Ground Clearance:

Approx. 5.1 in. (130 mm)

Dry Weight:

Approx. 573 lbs (260 kg)

Gross Vehicle Weight Rating Gvwr:

Not typically published as a distinct GVWR for Harley-Davidson motorcycles, but payload is based on rider, passenger, and cargo capacity.

Fuel Capacity:

4.5 US gallons (17.0 L)

🛡️ Safety Features

Safety Ratings:

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

Braking System:

Dual-piston front and rear disc brakes.

Lighting:

Halogen headlamp, LED tail light, incandescent turn signals.

Frame Construction:

Steel frame designed for stability and handling.

Tire Design:

Tubeless tires for improved puncture performance.

💡 Technology Features

Instrumentation:

Analog speedometer with integrated LCD odometer/trip meter, tachometer (often optional or integrated into speedo housing on custom models), fuel gauge, indicator lights (oil pressure, battery, neutral, turn signals, high beam).

Driver Assistance Features:

N/A (Basic rider aids only, no electronic driver assistance systems like ABS or traction control standard on this specific model, though some later models offered ABS as an option).

Connectivity Features:

N/A (No integrated Bluetooth or smartphone connectivity in 2008 models).

🔧 Maintenance

First Service:

Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes engine oil and filter change, primary chain tension adjustment, inspection of all critical components.

Subsequent Oil Change:

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

Spark Plug Replacement:

Typically every 10,000 - 15,000 miles (16,000 - 24,000 km), refer to manual for specific plug type and gap.

Drive Belt Inspection:

Inspect at every service, adjust tension as needed (typically at 1,000 mile service and every 5,000 miles thereafter).

Engine Oil Specification:

Harley-Davidson SYN3 SAE 20W50 or equivalent V-Twin motorcycle oil meeting Harley-Davidson specifications.

Transmission Oil Specification:

Harley-Davidson Formula + or equivalent.

Brake Fluid Specification:

DOT 4

Primary Chain Case Fluid:

Harley-Davidson Formula + or equivalent (shared with transmission in older models, but separate for this generation with distinct oil).

Common Issues Potential:

While generally reliable, potential issues can include stator failure, regulator/rectifier issues (leading to charging system problems), minor oil leaks from the primary or transmission seals, and occasional clutch drag if not properly maintained. EFI systems require clean fuel and proper operation of sensors.

Maintenance Importance:

Regular maintenance is crucial for the longevity and performance of the Evolution engine and drivetrain. The manual's detailed schedules and procedures are vital.

📚 Vehicle History

Brand Legacy:

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

Sportster Lineage:

The Sportster line has been in continuous production since 1957, evolving from lightweight sport bikes to more powerful cruisers. The 1200cc Evolution engine was introduced in 1988.

Production Location:

United States

Model Introduction Year:

The XL 1200C Custom variant, with its specific styling and features, was introduced in 1996.

🏆 Awards & Recognition

Awards History:

While specific awards for the 2008 XL 1200C are not widely documented, the Sportster line consistently garners praise for its iconic styling, V-twin character, and customization potential, making it a beloved platform in the cruiser market.