🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2008

Engine Code:

Evolution V-Twin

Chassis Code:

XL

👋 Introduction

Segment:

Cruiser motorcycle

Target Audience:

Owners, independent repair shops, and technicians servicing Harley-Davidson Sportster motorcycles.

Key Competitors Motorcycle:

Indian Scout, Triumph Bonneville, other custom cruiser motorcycles from Japanese and European manufacturers.

Manual Value Proposition:

Provides official, factory-level detail essential for accurate diagnosis and repair, saving money on dealership labor and ensuring proper maintenance.

📋 Manual Details

Coverage Scope:

Complete official factory service and repair for the 2008 Harley-Davidson XL1200C Sportster Custom.

Page Count Approximate:

Hundreds of pages (exact count not specified, but implies comprehensive coverage)

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, troubleshooting, performance tuning, torque specifications, component replacement (pistons, rings, valves, camshafts, crankshaft).

Fuel System:

Carburetor (Keihin CV 40mm), fuel injection systems (if applicable for specific variants, though 2008 XL1200C typically CV carb), fuel pump, fuel lines, fuel tank maintenance, diagnostics.

Ignition System:

Spark plugs, ignition coils, ignition module, timing, troubleshooting.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, taillights, turn signals), horn, fuses, relays, starter solenoid.

Transmission:

5-speed constant mesh gearbox, clutch operation and adjustment, primary drive system, final drive belt, lubrication, troubleshooting.

Chassis Frame:

Frame inspection, repair, lubrication points, steering head bearing adjustment.

Suspension Front:

Front fork service (oil changes, seal replacement), damping adjustments, troubleshooting.

Suspension Rear:

Rear shock absorber removal, installation, adjustment, and replacement.

Brakes Front:

Front brake caliper service, hydraulic system (master cylinder, brake lines, fluid), brake pad replacement, rotor inspection.

Brakes Rear:

Rear brake caliper service, hydraulic system, brake pad replacement, rotor inspection.

Wheels Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, wheel runout specifications.

Bodywork:

Fender removal and installation, fuel tank removal and installation, seat maintenance, handlebar replacement, instrument cluster service.

Emission Controls:

Information on emission-related components and their function as per factory specifications (often basic for this era).

Preventive Maintenance:

Detailed scheduled maintenance tasks including oil changes, filter replacements, spark plug checks, belt tension checks, brake fluid flushes, battery checks.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon faults across all major vehicle systems.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Overhaul:

Complete engine and transmission overhaul procedures.

Wiring Diagrams:

Comprehensive and clearly labeled electrical wiring diagrams for all circuits.

Torque Specifications:

Precise torque values for all fasteners critical to engine, chassis, and component assembly.

Depth Level:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical system troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (assuming standard PDF text layer)

Printability:

High-quality, printable pages allowing for a physical copy.

Binding Recommendation:

Print and bind for workshop use.

Paper Recommendation:

Glossy or semi-gloss paper for durability in a workshop environment.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

1200 cc (73.3 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.0:1

Horsepower Estimated:

Approx. 65-70 HP (Varies by tuning and specific output)

Torque Peak:

Approx. 70-75 lb-ft @ 3200 RPM (Varies by tuning)

Fuel Delivery:

Carburetor (Keihin CV 40mm) for most 2008 models

Fuel Type:

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

Oil Type:

Harley-Davidson 20W50 Synthetic or SAE 50 API SG or higher (refer to manual for specific recommendations)

Oil Capacity W Filter:

3.0 US quarts (2.8 Liters)

🔧 Transmission

Type:

5-speed, constant mesh

Primary Drive:

Chain, enclosed in a primary drive housing

Final Drive:

Belt drive

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

Harley-Davidson Transmission Fluid or SAE 75W-90 Hypoid Gear Oil (refer to manual for specific recommendations)

Transmission Oil Capacity:

24 US fluid ounces (0.71 Liters)

📐 Dimensions

Length:

90.5 in. (2299 mm)

Seat Height Laden:

26.5 in. (673 mm)

Ground Clearance:

4.25 in. (108 mm)

Dry Weight:

571 lbs (259 kg)

Gross Vehicle Weight Rating:

930 lbs (422 kg)

Fuel Capacity:

4.0 US gallons (15.1 Liters)

🛡️ Safety Features

Safety Certifications:

Meets all applicable US federal motor vehicle safety standards (FMVSS).

Braking System:

Dual-action, front and rear hydraulic disc brakes.

Lighting:

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

Frame Construction:

Steel frame and swingarm designed for stability and rigidity.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer (optional on some trims), odometer, trip meter, fuel gauge, indicator lights.

ABS:

Anti-lock Braking System (ABS) was generally an optional feature for the 2008 XL1200C Sportster Custom and not standard across all models.

Diagnostic Port:

On-board diagnostics (OBD-II or HD-specific diagnostic system) for fault code retrieval and system analysis.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.

Regular Oil Change:

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

Transmission Oil Change:

Every 10,000 miles (16,000 km) or 24 months, whichever comes first.

Drive Belt Inspection:

Check tension and condition every 5,000 miles (8,000 km).

Brake Fluid Flush:

Every 24 months, regardless of mileage.

Primary Chain Case Oil:

Harley-Davidson Primary Chaincase Lubricant or equivalent (refer to manual)

Fork Oil Type:

Harley-Davidson Formula + Transmission/Jiffy-Stand Oil or HD 10W Fork Oil (refer to manual for specific weight and quantity)

Common Wear Items:

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

Electrical Gremlins:

While generally robust, occasional loose connections or faulty grounds can cause intermittent electrical issues. The manual's wiring diagrams are crucial for diagnosis.

Carburetor Tuning:

CV carburetors can be sensitive to altitude and modifications; proper jetting and adjustment are key for optimal performance and fuel economy.

📚 Vehicle History

Brand Origin:

Harley-Davidson Motor Company, founded in 1903, Milwaukee, Wisconsin.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running and most iconic model families, known for its nimble handling and customizability.

Xl1200C Custom Features:

The 'Custom' variant typically features taller handlebars, a larger front wheel (often 19-inch), a teardrop-shaped fuel tank, and chrome detailing, emphasizing a classic custom look.

Production Location:

USA (Milwaukee, Wisconsin or Kansas City, Missouri)

🏆 Awards & Recognition

Motorcycle Reviews:

The Harley-Davidson Sportster line consistently received positive reviews for its classic styling, V-twin rumble, and customizability. The 2008 model was praised for its balance of classic looks and modern (for its time) engineering.