🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Year:

2008

Platform:

XL Series

Vin Prefix:

1HD1

👋 Introduction

Positioning:

The Harley-Davidson Sportster has long been a cornerstone of the brand, representing accessible performance and customization potential. The 2008 models continued this tradition with evolutionary updates to existing platforms.

Competitors 2008:

Key competitors in 2008 included Indian Chief, Triumph Bonneville, Kawasaki Vulcan, and Honda Shadow series. The Sportster's appeal often lay in its iconic V-twin engine, sound, and extensive customization options.

Features 2008:

The 2008 Sportster models offered a choice of 883cc and 1200cc Evolution engines, optional fuel injection (for certain models like the XL1200N 'Nightster'), 5-speed transmission, and a classic cruiser aesthetic with various factory customizations.

Value:

This comprehensive workshop manual provides DIY enthusiasts and professional mechanics with the essential technical data and procedures to maintain, diagnose, and repair their 2008 Harley-Davidson Sportster, saving time and money on dealership service.

📋 Manual Details

Models Covered:

All Sportster XL Series Models (e.g., XL883, XL883R, XL883C, XL883L, XL1200N, XL1200C, XL1200R, XL1200L, XL50)

Engine Variants Covered:

883cc Evolution V-Twin, 1200cc Evolution V-Twin

Regions Covered:

North America, Europe, Asia (general applicability)

Estimated Pages:

800+

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, lubrication, cooling system, fuel system (carburetor/EFI), ignition system, exhaust system, performance tuning.

Transmission Drivetrain:

Clutch, gearbox, primary drive, final drive (belt/chain), maintenance, repair, troubleshooting.

Chassis Suspension:

Frame, front suspension (forks), rear suspension (shocks), wheel bearings, steering system, alignment.

Brakes:

Hydraulic brake system (front and rear), brake fluid specifications, caliper maintenance, disc inspection, bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting (headlight, taillight, turn signals), instrumentation, wiring diagrams, diagnostic codes (DTCs).

Fuel System:

Carbureted models (Mikuni HSR42/45, Keihin CV40), Fuel Injection (EFI) models (throttle body, fuel pump, injectors, ECM), fuel tank, lines, and filters.

Bodywork Fittings:

Body panels, fenders, seat, fuel tank removal/installation, handlebars, mirrors, foot controls, lighting fixtures.

Maintenance:

Routine service intervals, oil changes, filter replacements, spark plug service, brake pad replacement, belt tensioning, tire pressure checks.

Troubleshooting:

Diagnostic flowcharts for common problems, electrical issues, engine performance problems, starting issues, and drivability concerns.

Repair Rebuild:

Complete engine rebuild procedures, transmission overhaul, fork seal replacement, brake caliper rebuild, electrical component repair.

Specifications Data:

Torque specifications for all fasteners, engine clearances, fluid capacities, electrical component testing procedures, diagnostic trouble code (DTC) definitions and troubleshooting.

Depth:

Comprehensive, from basic maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures for electrical and mechanical systems.

📊 Manual Specifications

Format:

PDF

Searchability:

Text-searchable PDF for quick information retrieval.

Quality:

High-resolution scans of original factory service manuals, ensuring clarity of text and diagrams.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Evolution V-Twin (Air-Cooled)

Displacement 883Cc:

883 cc (53.9 cu in)

Displacement 1200Cc:

1200 cc (73.3 cu in)

Horsepower Approx 883Cc:

53 hp @ 6000 rpm (approximate)

Torque Approx 883Cc:

54 lb-ft @ 3500 rpm (approximate)

Horsepower Approx 1200Cc:

67 hp @ 6000 rpm (approximate)

Torque Approx 1200Cc:

70 lb-ft @ 3500 rpm (approximate)

Carbureted Models:

Mikuni HSR42 or Keihin CV40 (depending on sub-model)

Efi Models:

Electronic Sequential Port Fuel Injection (ESPFI) on specific models (e.g., XL1200N)

Ignition Type:

Electronic Ignition

Oil Type Recommendation:

Harley-Davidson 20W50 SYN3 or equivalent API SG certified lubricant

Cooling Method:

Air-Cooled

🔧 Transmission

Transmission Type:

5-Speed Manual Constant Mesh

Transmission Variants:

N/A (all 2008 Sportsters used the 5-speed)

Primary Drive:

Chain Drive (Wet Clutch)

Final Drive:

Belt Drive

Transmission Oil Type:

Harley-Davidson Formula+ or equivalent primary lubricant

📐 Dimensions

Length Approx:

85.1 in (2161 mm) - varies by model

Width Approx:

34.5 in (876 mm) - varies by model

Seat Height Laden Approx:

26.0 in (660 mm) - varies by model

Dry Weight Approx Kg:

255 kg (562 lbs) - varies by model

Gross Vehicle Weight Rating Gvw:

850 lbs (385 kg) - varies by model

Fuel Tank Capacity:

3.1 US gal (11.7 L) - varies by model

Oil Capacity:

3.0 US qt (2.8 L) with filter

Front Tire Size Typical:

MT90B16 (or similar 16-inch radial)

Rear Tire Size Typical:

150/80B16 (or similar 16-inch radial)

Wheel Bolt Pattern:

N/A (Solid Hubs, standard Harley bolt pattern where applicable)

🛡️ Safety Features

Crash Test Ratings:

Motorcycle safety is not rated via formal crash tests like automobiles. Focus is on rider protection and vehicle stability.

Braking System:

Hydraulic disc brakes front and rear. ABS was not standard on most 2008 Sportster models, but became available on select models later.

Lighting:

Halogen headlight, LED taillight, amber front/rear turn signals.

Frame Construction:

Steel cradle frame designed for stability and rider feedback.

💡 Technology Features

Audio System:

Base models typically did not feature integrated audio systems. Aftermarket options are common.

Instrumentation:

Analog speedometer with tachometer (optional on some models), odometer, trip meter, fuel gauge (on some models), indicator lights. Diagnostic codes displayed via odometer or specific indicator if equipped with EFI.

Rider Aids:

Limited to ABS on select models (not standard on most 2008 Sportsters). Focus is on mechanical feedback and rider control.

Smart Phone Integration:

N/A (No factory integration on 2008 models)

🔧 Maintenance

Oil Change Interval:

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

Primary Fluid Change Interval:

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

Transmission Fluid Change Interval:

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

Spark Plug Replacement Interval:

Every 10,000 miles (16,000 km) or as needed

Drive Belt Tension Check:

Every 5,000 miles (8,000 km)

Engine Oil Specification:

Harley-Davidson SYN3 20W50 or equivalent API SG, JASO FD rated (check manual for exact specs)

Primary Transmission Fluid:

Harley-Davidson Formula+ or equivalent primary lubricant

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified for specific applications)

Common Issues 2008 Sportster:

Potential for oil leaks (especially around primary cover and rocker boxes), clutch cable adjustment, starter solenoid issues on older models, carburetor performance tuning. Fuel injection models may experience minor electrical gremlins if not properly maintained.

Engine Mount Torque:

Refer to manual; typically ~30-40 ft-lbs

Wheel Axle Torque:

Refer to manual; typically ~50-70 ft-lbs front/rear

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser lifestyle.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running platforms, evolving from earlier Ironhead engines to the Evolution 'Evo' engine starting in 1986. The 2008 models are part of the Evolution-era Sportsters.

Manufacturing Location:

United States (Various Harley-Davidson facilities)

Sportster Production History:

1957-Present (with continuous evolution of engines, frames, and features)

🏆 Awards & Recognition

Sportster Impact:

The Sportster line itself is a recognized icon in motorcycle history, representing a significant segment of the cruiser market and a platform for customization for decades.