🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster 1200 Low

Year:

2008

Platform:

XL

Engine Family:

Evolution

Vin Code Engine:

G (for 1200cc Evolution)

👋 Introduction

Market Segment:

Cruiser motorcycle, targeted at riders seeking a classic Harley-Davidson experience with a lower seat height for easier handling and rider comfort.

Competitors:

Competes with other mid-size V-twin cruisers from manufacturers like Indian, as well as custom and Japanese cruiser offerings.

Low Seat Height:

The 'Low' designation signifies a factory-configured lower seat height and potentially revised suspension for enhanced rider accessibility and stability at low speeds.

V Twin Engine:

Features the iconic Harley-Davidson air-cooled Evolution V-twin engine, known for its torque and distinctive sound.

Customization Potential:

Sportster models are highly customizable, with a vast aftermarket support for personalization and performance upgrades.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Fuel System, Ignition System, Exhaust System, Cooling System (if applicable), Frame, Bodywork, Instruments, Controls, Maintenance, Troubleshooting, Diagnostics, Specifications, Wiring Diagrams.

Page Count:

Estimated 400-600 pages (typical for a comprehensive service manual of this era).

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, inspection, assembly, overhaul procedures for top end (cylinder heads, valves, camshafts) and bottom end (crankshaft, connecting rods, pistons), timing procedures, valve adjustment, torque specifications.

Fuel System:

Carburetor (Keihin CV 40mm typical for this model) service, adjustment, and troubleshooting; fuel pump operation (if applicable, though this model is likely carbureted); fuel filter replacement; fuel tank maintenance.

Ignition System:

Ignition module testing, coil specifications, spark plug selection and gap, timing adjustments (if adjustable), troubleshooting ignition faults.

Drivetrain:

Clutch operation, adjustment, and replacement; primary drive chain inspection and tensioning; transmission gear shifting mechanisms, maintenance, and lubrication; final drive belt inspection, tensioning, and replacement.

Electrical System:

Wiring diagrams for all circuits, battery maintenance and testing, starter motor operation, charging system (stator, regulator/rectifier), lighting circuits, horn, ignition switch, fuses and relays, instrument cluster functions and troubleshooting.

Brakes:

Front and rear brake system inspection, pad replacement, caliper service, hydraulic system bleeding, master cylinder and slave cylinder maintenance, brake fluid specifications and replacement intervals.

Suspension Steering:

Front fork disassembly, seal replacement, oil level and type, rear shock absorber inspection and adjustment, steering head bearing adjustment and maintenance, wheel bearing inspection and replacement.

Frame Bodywork:

Frame inspection for damage, body panel removal and installation, seat maintenance, fender mounting, fuel tank mounting, handlebar and control mounting.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, tire pressure checks, brake fluid checks, battery terminal cleaning.

Troubleshooting:

Systematic diagnostic flowcharts for common problems (e.g., no start, poor running, electrical issues), symptom-based troubleshooting guides.

Major Repairs:

Engine rebuild procedures, transmission overhauls, complete brake system servicing, suspension component replacement, electrical system diagnostics and repair.

Technical Specifications:

Torque values for all fasteners, fluid capacities, recommended lubricants and fluids, electrical specifications (resistance, voltage), engine performance data.

Depth:

Comprehensive. Covers everything from basic owner maintenance to full engine and transmission rebuilds, including in-depth electrical system diagnostics and wiring diagrams.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Searchability:

Likely text-searchable if professionally scanned, allowing for quick location of specific information.

Print Quality:

Dependent on the source scan, but ideally clear text and legible diagrams.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200 cc (73.4 cubic inches)

Bore X Stroke:

3.496 in x 3.813 in (88.8 mm x 96.8 mm) - typical for 1200 Evolution

Compression Ratio:

Approximately 9.0:1

Cylinder Heads:

Pushrod-actuated overhead valves, 2 valves per cylinder

Horsepower:

Estimated 60-70 HP (at crank), depending on specific tuning and emission controls.

Torque:

Estimated 68-75 ft-lbs (at crank), delivered at low RPM.

Fuel Delivery:

Carbureted (typically Keihin CV 40mm)

Fuel Type:

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

Oil Capacity:

Approximately 3.0 quarts (2.8 liters) with filter change.

Oil Type:

Harley-Davidson Genuine V-Twin Motorcycle Oil 20W-50 or equivalent API CI-4 specification.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive:

Duplex chain, 1.371:1 ratio

Final Drive:

Belt drive, 3.15:1 ratio

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil:

Harley-Davidson Genuine Formula+ or equivalent SAE 50 gear oil.

Transmission Oil Capacity:

Approximately 0.95 quarts (0.9 liters)

📐 Dimensions

Length:

Approximately 88.0 inches (2235 mm)

Seat Height Unladen:

Approx. 26.0 inches (660 mm) - typical for Low model

Ground Clearance:

Approx. 4.5 inches (114 mm)

Dry Weight:

Approximately 556 lbs (252 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 930 lbs (422 kg)

Fuel Capacity:

3.5 gallons (13.2 liters)

Front Tire Size:

MT90B16 (or similar, e.g., 130/90B16)

Rear Tire Size:

150/80B16 (or similar)

Wheel Type:

Usually cast aluminum wheels on Low models.

Wheelbase:

Approximately 59.6 inches (1515 mm)

🛡️ Safety Features

Crash Test Ratings:

Motorcycle safety is not typically rated by standardized crash test agencies like NHTSA for passenger vehicles. Safety relies on rider skill and adherence to safety practices.

Braking System:

Dual-piston caliper front brake, single-piston caliper rear brake. ABS was typically an optional feature on some Harley-Davidson models of this era, but less common on Sportsters.

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Frame Construction:

Steel frame and swingarm designed for stability and rider support.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer (often integrated or optional), odometer, trip meter, indicator lights for turn signals, oil pressure, high beam, and neutral.

ABS:

Antilock Braking System (ABS) was typically an optional feature for Harley-Davidson models of this period, not standard.

Smartphone Integration:

No integrated smartphone connectivity or infotainment systems like Apple CarPlay/Android Auto. Connectivity would be through aftermarket accessories.

🔧 Maintenance

Oil Change Interval:

Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first. Refer to manual for precise intervals.

Primary Chain Tension:

Check and adjust every 2,500 miles (4,000 km).

Belt Drive Inspection:

Inspect for wear and adjust tension as needed at regular service intervals, typically every 5,000 miles (8,000 km).

Spark Plug Replacement:

Recommended at 10,000-15,000 miles (16,000-24,000 km) or as indicated by wear.

Brake Fluid Flush:

Every 2 years or as recommended by Harley-Davidson, using DOT 4 fluid.

Engine Oil Type:

Harley-Davidson Genuine V-Twin Motorcycle Oil 20W-50

Transmission Oil Type:

Harley-Davidson Genuine Formula+ or SAE 50 Gear Oil

Brake Fluid Type:

DOT 4

Fork Oil Type:

Harley-Davidson Type E or equivalent (e.g., Spectro HD Fork Oil) - 15 WT is common.

Carburetor Tuning:

CV carburetors can require periodic adjustment for optimal performance and fuel economy. Idle speed and mixture adjustments are common.

Clutch Cable Adjustment:

Clutch cable can stretch over time, requiring adjustment for proper engagement and disengagement.

Belt Drive Wear:

The final drive belt can wear and require replacement; proper tension is critical to prevent premature wear.

Electrical Connections:

Corrosion or loose connections in electrical connectors can lead to intermittent faults, especially in humid environments.

📚 Vehicle History

Harley Davidson Legacy:

Harley-Davidson boasts a long and storied history dating back to 1903, synonymous with American motorcycling culture, V-twin engines, and a strong emphasis on rider freedom.

Sportster Lineage:

The Sportster line itself dates back to 1957, evolving from earlier 'K' models. It represents Harley-Davidson's sportier offering, distinct from the larger Big Twin models.

2008 Sportster Updates:

While the core Evolution engine remained, the 2008 model year saw various refinements. For the 'Low' variant, the primary focus was on ergonomic adjustments for accessibility.

Manufacturing Location:

Harley-Davidson motorcycles, including Sportsters, are primarily manufactured in the United States (e.g., Milwaukee, Wisconsin; York, Pennsylvania).

🏆 Awards & Recognition

Model Recognition:

The Sportster line consistently receives recognition for its iconic styling, customization potential, and its role in defining the cruiser motorcycle segment. Specific awards for the '2008 Sportster 1200 Low' are less likely to be documented as distinct accolades, but rather as part of the model's overall success within the cruiser market.