🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster 1200 Roadster

Year:

2008

Model Code:

XL1200R

Engine Type:

Air-Cooled, Evolution V-Twin

Engine Displacement:

1200cc (73.4 cubic inches)

Fuel System:

Fuel Injection (EFI)

Manual Product Name:

Harley Davidson Sportster 1200 Roadster 2008 Service Repair Manual

👋 Introduction

Vehicle Class:

Cruiser Motorcycle

Target Audience:

Riders seeking a classic Harley-Davidson experience with a focus on performance and handling, DIY enthusiasts, independent repair shops.

Key Competitors:

Indian Chief, Triumph Bonneville, Honda Shadow, Yamaha V-Star.

Design Philosophy:

Sporty and agile cruiser, blending classic Harley-Davidson styling with responsive handling and a powerful engine for spirited riding.

Distinctive Elements:

2-into-2 exhaust, 16-inch front and rear wheels, lowered front suspension, drag-style handlebars, solo seat, chromed components.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

Page Count:

Estimated 700+ pages (typical for this model year and depth)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, disassembly, assembly, tuning, lubrication, cooling system, oil pump, oil filter, primary drive, clutch.

Engine Electrical:

Ignition system, starter motor, charging system (alternator, regulator), battery, fuel injection system (ECM, sensors, injectors), wiring diagrams, troubleshooting electrical faults.

Transmission:

Gearbox operation, maintenance, clutch service, primary chain adjustment, gear ratios, troubleshooting transmission issues.

Chassis Suspension:

Front fork service (oil changes, seal replacement), rear shock absorber maintenance, wheel bearing replacement, steering head bearing adjustment.

Brakes:

Front and rear brake system service, hydraulic system bleeding, brake pad replacement, rotor inspection and replacement, troubleshooting brake issues.

Fuel System:

Fuel tank removal and installation, fuel filter replacement, fuel pump testing, throttle body inspection and cleaning, EFI diagnostics.

Exhaust System:

Exhaust component inspection, muffler replacement, gasket replacement.

Bodywork Frame:

Fender removal and installation, seat removal, fuel tank mounting, frame inspection, fairing and panel removal (if applicable).

Wheels Tires:

Tire pressure checks, wheel removal and installation, spoke tensioning (if applicable), rim inspection.

Lighting Indicators:

Headlight, taillight, turn signals, brake light maintenance and troubleshooting.

Diagnostic Troubleshooting:

Systematic diagnostic procedures, fault code identification, common problem solutions, symptom-based troubleshooting charts.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, air filter cleaning/replacement, brake fluid checks, battery maintenance.

Major Repairs:

Engine rebuilds, transmission overhauls, fork seal replacement, brake caliper rebuilds, electrical component replacement.

Component Removal Installation:

Detailed instructions for removing and reinstalling all major and minor components.

Wiring Diagrams:

Comprehensive, color-coded wiring schematics for all electrical systems.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Special Tools:

Identification and usage of specialized tools required for specific procedures.

Diagnostic Level:

Advanced diagnostic procedures, including EFI system analysis and component testing.

Rebuild Level:

Complete engine and transmission disassembly, inspection, repair, and reassembly procedures.

Electrical Troubleshooting:

Detailed troubleshooting trees for electrical system faults.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Fully searchable text content for quick information retrieval.

Print Quality:

High-resolution, printable pages allowing for clear diagrams and text.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Configuration:

45-degree V-twin, OHV, 2 valves per cylinder

Bore X Stroke:

3.43 in. x 4.13 in. (87.0 mm x 104.0 mm)

Compression Ratio:

9.0:1

Cooling System:

Air-Cooled

Oil Capacity:

3.0 US qt (2.8 L)

Recommended Oil Grade:

Harley-Davidson 20W-50 SYN3 or equivalent API SG or higher, JASO FD certified motorcycle oil.

Horsepower:

Approx. 65-70 HP (at crankshaft, estimated)

Torque:

Approx. 70-75 ft-lbs (at crankshaft, estimated)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Tank Capacity:

4.0 US gal (15.1 L)

Fuel Type:

Unleaded premium gasoline, 91 octane (R+M)/2 or higher

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

9-plate, wet, multi-plate

Primary Drive:

45-tooth, 1.5 in. pitch, 17-tooth, 1.5 in. pitch, duplex primary chain

Final Drive:

Belt Drive, 32 tooth front pulley, 68 tooth rear pulley, 14mm pitch

Gear Ratios:

1st: 10.110, 2nd: 7.570, 3rd: 5.520, 4th: 4.510, 5th: 3.750

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent SAE 50 motorcycle transmission oil.

Transmission Fluid Capacity:

2.5 US qt (2.4 L)

📐 Dimensions

Length:

88.8 in. (2255 mm)

Width:

33.5 in. (850 mm)

Height:

47.2 in. (1199 mm)

Wheelbase:

60.0 in. (1524 mm)

Ground Clearance:

4.7 in. (119 mm)

Dry Weight:

567 lbs (257 kg)

Gross Vehicle Weight Rating:

960 lbs (435 kg)

Saddlebag Capacity:

N/A (No factory saddlebags)

Front Tire Size:

100/55R16 55H

Rear Tire Size:

150/70R16 71H

Wheel Type:

Chrome, cast aluminum

Wheelbase Bolt Pattern:

5x114.3mm (Rear)

🛡️ Safety Features

Crash Test Ratings:

Not Applicable (Motorcycle)

Braking System:

Dual-piston front caliper with 11.5 in. (292 mm) rotor; Dual-piston rear caliper with 11.5 in. (292 mm) rotor.

ABS:

Optional (Check VIN for specific vehicle)

Lighting:

Halogen headlight, LED tail light, standard turn signals.

Mirrors:

Standard handlebar-mounted mirrors

💡 Technology Features

Display Type:

Analog speedometer with integrated LCD display for odometer, trip meter, clock, and gear indicator.

Audio System:

N/A (No factory audio system)

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 12 months, whichever comes first.

Subsequent Service:

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

Engine Oil Change:

Recommended every 2,500 miles (4,000 km) or annually.

Primary Chain Adjustment:

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

Spark Plugs:

Inspect every 10,000 miles (16,000 km), replace as needed.

Brake Fluid:

Flush and replace every 2 years.

Engine Oil:

Harley-Davidson 20W-50 SYN3 or equivalent API SG or higher, JASO FD certified motorcycle oil.

Transmission Fluid:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent SAE 50 motorcycle transmission oil.

Primary Chaincase Oil:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent SAE 50 motorcycle transmission oil.

Brake Fluid:

DOT 4, SAE J1703

Fork Oil:

Harley-Davidson front fork oil or equivalent SAE 10W motorcycle fork oil (capacity and viscosity may vary by rider preference).

Common Wear Items:

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

Potential Electrical Concerns:

Battery terminal corrosion, charging system issues (regulator/stator) under high mileage use.

Engine Considerations:

Regular oil changes are critical for longevity; some early models may exhibit oil leaks if not maintained properly.

📚 Vehicle History

Brand Founding:

1903, Milwaukee, Wisconsin, USA

Sportster Line Introduction:

1957

Roadster Variant Origin:

The 'Roadster' designation has appeared periodically within the Sportster line, emphasizing sportier handling and appearance.

2008 Updates:

For 2008, Sportster models featured fuel injection as standard across the range. The Roadster received specific styling cues and chassis tuning for a sportier feel.

Manufacturing Location:

United States

🏆 Awards & Recognition

Specific Awards:

While specific model awards for the 2008 Sportster 1200 Roadster are not prominently documented, Harley-Davidson motorcycles consistently receive recognition for their brand heritage, iconic styling, and rider community engagement.