🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL 1200R Sportster Roadster

Year:

2008

Engine Family:

Evolution V-Twin

Sportster Platform:

XL Series

👋 Introduction

Motorcycle Segment:

Cruiser / Performance Cruiser (Sportster model emphasizes sportier riding characteristics within the cruiser segment).

Key Competitors 2008:

Competes with other mid-size V-twin cruisers from manufacturers like Indian, Triumph (Bonneville), and some Japanese offerings focusing on retro styling and V-twin character, though Harley-Davidson's brand loyalty and specific engine feel are differentiating factors.

Xl1200R Distinction:

The 'R' designation typically signifies a more performance-oriented version, often featuring a larger front brake rotor and dual front disc brakes (confirming this for the '08 1200R is crucial, as it was a common 'R' differentiator), higher suspension travel, and a more aggressive riding posture compared to other Sportster models of the era.

Owner Benefit:

Empowers owners and independent mechanics with the precise knowledge required to maintain, diagnose, and repair the 2008 XL 1200R Sportster Roadster, ensuring longevity and optimal performance.

📋 Manual Details

Primary Coverage:

2008 Harley-Davidson XL 1200R Sportster Roadster

Estimated Pages:

Extensive (typically 500-800+ pages for a comprehensive service manual)

Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the Evolution 1200cc V-Twin engine, including top-end (cylinder heads, valves, camshafts) and bottom-end (crankshaft, connecting rods, pistons).

Fuel System:

Carburetor (Keihin CV 40mm), fuel tank, fuel pump, fuel lines, fuel filter servicing and troubleshooting.

Ignition System:

Ignition module, spark plugs, ignition coil, wiring, timing adjustment.

Transmission:

5-speed constant mesh transmission, clutch (primary and secondary), transmission oil, internal components, shift mechanism.

Drive Train:

Primary drive system (chain, compensator sprocket, clutch hub), final drive (belt drive system, belt tension adjustment, pulley inspection).

Brakes:

Front and rear brake systems (calipers, master cylinders, brake lines, brake pads, rotors), hydraulic system bleeding, troubleshooting.

Suspension:

Front fork (telescopic, oil change, seal replacement, spring inspection), rear shock absorbers (adjustment, replacement), swingarm and linkage.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlamp, tail lamp, turn signals), instrumentation, wiring diagrams, fuses, relays.

Chassis And Frame:

Frame inspection, steering head bearings, wheel bearings, swingarm pivot bearings.

Bodywork And Trim:

Fender removal/installation, fuel tank mounting, seat removal/installation, handlebars, control levers, mirrors.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain lubrication/adjustment, belt tension checks, brake fluid checks, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and braking issues. Includes symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component disassembly, repair, and reassembly for all major systems. Includes torque specifications for critical fasteners.

Rebuilds:

Complete engine and transmission rebuild procedures, including machining specifications and tolerances.

Electrical Diagnostics:

Detailed wiring diagrams, component testing procedures, and troubleshooting for electrical faults.

Suspension Service:

Fork seal replacement, fork oil changes, rear shock absorber replacement, and bearing service.

Depth:

Comprehensive, covering everything from basic rider maintenance to complete engine and transmission overhauls. Includes diagnostic procedures and specifications for professional technicians.

📊 Manual Specifications

File Type:

PDF

Image Resolution:

High resolution, ensuring clear display of all diagrams, schematics, and illustrations. Optimized for readability on screen and potential printing.

Binding:

Not Applicable (Digital PDF)

Paper Quality:

Not Applicable (Digital PDF)

Text Search:

Searchable text allows for quick location of specific topics, procedures, and specifications.

Reader Recommendation:

Adobe Acrobat Reader recommended for optimal viewing of all images and graphics.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1202 cc (73.3 cubic inches)

Bore X Stroke:

3.500 in x 3.812 in (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Valve Train:

Pushrod-actuated, overhead valves, 2 valves per cylinder

Horsepower Estimate:

Approx. 65-70 HP (at crank, varies by source and specific tuning)

Torque Estimate:

Approx. 70-75 lb-ft @ 3200 RPM (at crank)

Carburetor:

Keihin CV 40mm (Constant Velocity) with accelerator pump

Fuel Type:

Unleaded gasoline, minimum 87 octane

Oil Type:

Harley-Davidson Genuine V-Twin 20W50 (or equivalent API CI-4 or higher rated oil)

Oil Capacity With Filter:

Approx. 3.0 US quarts (2.8 liters)

Spark Plugs:

Harley-Davidson P/N 32318-99 (or equivalent like NGK DCPR8E)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Optional Transmissions:

N/A for this model year and trim

Primary Drive:

Chain drive, 34-tooth engine sprocket, 25-tooth transmission input shaft sprocket (1.36:1 ratio)

Final Drive:

Belt drive, 68-tooth rear pulley, 29-tooth front pulley (2.34:1 ratio)

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson Formula Plus (or equivalent SAE 50 motorcycle transmission oil)

Transmission Oil Capacity:

Approx. 24 US fluid ounces (0.71 liters)

📐 Dimensions

Length:

88.2 in (2240 mm)

Width Handlebars:

33.5 in (850 mm)

Height Seat:

29.0 in (735 mm) (laden)

Ground Clearance:

4.5 in (114 mm)

Wheelbase:

60.0 in (1525 mm)

Dry Weight:

Approx. 545 lbs (247 kg)

Wet Weight:

Approx. 575 lbs (261 kg) (fully fueled, with all fluids)

Gross Vehicle Weight Rating Gvwr:

Approx. 950 lbs (431 kg)

Fuel Tank Capacity:

4.0 US gallons (15.1 liters)

🛡️ Safety Features

Safety Certification:

Meets applicable Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.

Braking System:

Dual front disc brakes (292mm rotors) and single rear disc brake (292mm rotor), with hydraulic actuation. The 'R' model's dual front discs are a key safety and performance feature.

Lighting:

Halogen headlamp, LED tail lamp, amber incandescent front and rear turn signals.

Frame Construction:

Steel, backbone, and downtube frame designed for stability and handling.

Tires:

Tubeless tires: Front 100/90-19, Rear 150/80B16. Correct tire pressures are critical for safe handling.

💡 Technology Features

Infotainment System:

Basic; typically features a speedometer, tachometer (optional or integrated with speedo on some variants), odometer, trip meter, and indicator lights. No complex infotainment or navigation systems present on this model.

Electronic Aids:

None typically found on this model. Focus is on rider experience and mechanical feedback.

Connectivity Features:

N/A. This model predates the widespread integration of Bluetooth or smartphone connectivity in motorcycles.

🔧 Maintenance

First Service:

Typically at 1,000 miles (1,600 km) for an initial oil and filter change, drive belt check, and general inspection.

Subsequent Oil Change:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Includes filter replacement.

Drive Belt Tension Check:

Every 5,000 miles (8,000 km).

Spark Plug Replacement:

Typically at 10,000 - 15,000 miles (16,000 - 24,000 km), or as per manual recommendation.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Engine Oil Viscosity:

20W50 (Harley-Davidson Genuine V-Twin or SAE 20W50 API CI-4 or higher)

Transmission Oil Viscosity:

SAE 50 (Harley-Davidson Formula Plus or equivalent)

Primary Chain Case Oil:

Harley-Davidson Primary Chaincase Lubricant (or equivalent heavy-duty chain lube/oil)

Brake Fluid Type:

DOT 4 (low moisture absorption type)

Common Wear Items:

Clutch plates, belt drive components (pulley wear, belt replacement), fork seals, wheel bearings, and brake pads are common wear items requiring periodic inspection and replacement.

Ignition Module Failures:

Older ignition modules could be prone to failure, leading to no-spark conditions. (Check for updates/revisions for this year).

Carburetor Tuning:

CV carburetors can sometimes require fine-tuning or cleaning, especially if the motorcycle has been sitting or subjected to atmospheric changes.

Belt Tension Issues:

Improper belt tension can lead to premature wear of the belt and pulleys or affect handling.

📚 Vehicle History

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and strong brand culture. The Sportster line, introduced in 1957, is its longest-running model family, evolving significantly over decades.

Sportster Development:

The XL series has seen numerous engine displacements and stylistic updates. The 1200cc Evolution engine became a staple in the late 1980s, offering improved performance and reliability over earlier Ironhead engines. The 'R' variant, particularly in the 2000s, was positioned as a more performance-focused Sportster.

Manufacturing Location:

United States (e.g., Milwaukee, Wisconsin or Kansas City, Missouri assembly plants)

Production Period Xl1200R:

The XL1200R was produced for several years in the early to mid-2000s, with the 2008 model representing a refined version within the Evolution Sportster lineage.

🏆 Awards & Recognition

Model Awards:

While specific awards for the 2008 XL 1200R might not be widely publicized, the Harley-Davidson Sportster line has consistently been recognized for its iconic status, rider engagement, and V-twin character, often featuring in 'best cruiser' or 'classic motorcycle' lists.

Reliability Perception:

Generally good, with the Evolution engine being a robust and well-understood powerplant. Maintenance adherence is key to longevity.