🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XL1200C

Year:

2008

Model Variant:

Custom

Chassis Code:

XL1200C

👋 Introduction

Positioning:

The Harley-Davidson Sportster series, particularly the XL1200C Custom, represents a blend of classic styling and performance within the cruiser segment, appealing to riders seeking a customizable and iconic V-twin experience.

Competitors:

Competes with other mid-size cruisers from brands like Indian Motorcycle, Triumph, and Japanese manufacturers offering similar displacement and cruiser aesthetics.

Engine Type:

Air-cooled, 1200cc Evolution V-Twin engine.

Styling:

Classic cruiser styling with a prominent V-twin engine, chrome accents, and a custom aesthetic.

Customization:

Designed for customization, with a wide range of factory and aftermarket accessories available.

Utility:

Essential for owners and independent repair shops to perform all levels of maintenance, repair, and diagnosis on the 2008 XL1200C.

📋 Manual Details

Primary Coverage:

Service and Repair

Secondary Coverage:

Overhaul and Troubleshooting

Estimated Pages:

Over 400

Type:

Workshop Manual / Service Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Complete disassembly, assembly, inspection, and repair of the Evolution V-Twin engine.

Fuel System:

Carburetor (Keihin CV) or Fuel Injection (EFI) system diagnosis and repair, fuel pump, fuel filter replacement.

Transmission:

5-speed Cruise Drive transmission removal, disassembly, inspection, assembly, and adjustment.

Electrical System:

Wiring diagrams, battery, ignition system, lighting, starter, charging system, instrument cluster, fault diagnosis.

Brakes:

Hydraulic brake system inspection, service, bleeding, pad and rotor replacement, master cylinder and caliper overhaul.

Suspension:

Front fork (telescopic) and rear shock absorber servicing, fluid replacement, seal replacement, inspection.

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearing replacement, tire mounting and balancing.

Bodywork And Fittings:

Fender removal and installation, fuel tank removal and installation, seat servicing, handlebars, mirrors.

Cooling System:

Air-cooled engine principles, but covers any associated fluid checks for specific components if applicable.

Exhaust System:

Exhaust pipe and muffler removal, installation, and inspection for leaks.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable).

Diagnostics:

Troubleshooting guides for common problems, diagnostic fault codes (if EFI), electrical system troubleshooting.

Repair:

Detailed step-by-step instructions for component repair and replacement across all major systems.

Overhaul:

Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, and reassembly.

Calibration:

Carburetor tuning and adjustment, fuel injection idle speed control and throttle body synchronization (if applicable).

Installation:

Guidance on installing genuine Harley-Davidson or approved aftermarket parts.

Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics.

Detail Level:

Detailed torque specifications, clearances, measurements, and assembly sequences.

Diagnostic Tools:

Mentions and utilizes standard automotive and motorcycle diagnostic tools where applicable.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text (OCR'd)

Printability:

Printable

Quality:

High resolution, clear text and diagrams

Type:

N/A (Digital PDF)

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Family:

Evolution (Big Twin Sportster)

Displacement:

1199 cc (73.2 cu in)

Bore:

3.496 in (88.8 mm)

Stroke:

3.800 in (96.5 mm)

Compression Ratio:

9.7:1

Cylinder Configuration:

90-degree V-twin

Valvetrain:

OHV, 2 valves per cylinder, pushrod actuated

Cooling:

Air-cooled

Horsepower:

Approx. 65-70 HP (estimated, varies by specific dyno and conditions)

Torque:

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

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV 40mm Carburetor (depending on market/variant)

Fuel Type:

Unleaded gasoline, minimum 91 octane (Research Octane Number)

Oil Type:

Harley-Davidson SYN3 (SAE 20W-50) or equivalent API SG/SH/SJ certified synthetic motorcycle oil.

Oil Capacity:

3.0 US quarts (2.8 liters) with filter change.

🔧 Transmission

Type:

5-speed Cruise Drive, constant mesh

Clutch:

Multi-plate, wet type, hydraulic actuation

Primary Drive:

Chain, 34/46 ratio (1.353:1)

Final Drive:

Belt, 32/65 ratio (2.031:1)

Gear Ratios:

1st: 10.110, 2nd: 7.000, 3rd: 4.887, 4th: 3.745, 5th: 3.000

Transmission Fluid Type:

Harley-Davidson Formula + Transmission Lubricant (or equivalent SAE 80W-90 API GL-5 gear oil)

Transmission Fluid Capacity:

26 US fluid ounces (0.77 liters)

📐 Dimensions

Length:

90.4 in (2296 mm)

Width:

32.3 in (820 mm)

Height:

47.5 in (1207 mm)

Wheelbase:

60.0 in (1524 mm)

Ground Clearance:

4.25 in (108 mm)

Dry Weight:

567 lbs (257 kg)

Gross Vehicle Weight Rating (Gvwr):

960 lbs (435 kg)

Fuel Tank Capacity:

5.0 US gallons (19 liters)

Front Tire Size:

100/90-19 57H

Rear Tire Size:

150/80B16 71H

Front Wheel:

19-inch, Chrome laced steel

Rear Wheel:

16-inch, Chrome laced steel

Wheel Bolt Pattern:

N/A (Shaft/Belt Drive Specific Hub)

🛡️ Safety Features

Crash Test Ratings:

Not applicable for motorcycles in the same manner as automobiles.

Brakes:

Dual-piston front caliper with 300mm disc; Single-piston rear caliper with 292mm disc.

ABS:

Optional Antilock Braking System (ABS) available on some models/markets.

Lighting:

Halogen headlight, LED tail light, turn signals.

Handlebars:

Forward-mounted handlebars for an engaged riding position.

💡 Technology Features

Instrument Cluster:

Analog speedometer with integrated LCD display for odometer, trip meter, clock, and gear indicator (if applicable). Tachometer typically an optional add-on or integrated into specific gauge clusters.

Audio System:

No integrated audio system as standard on the XL1200C; aftermarket options are common.

ABS:

Optional ABS system available, providing enhanced braking control.

Diagnostic Ports:

Data link connector for diagnostic tools (e.g., Harley-Davidson Dealer Diagnostic System - HD-DD). This manual will guide users on accessing and interpreting diagnostic data.

ECU:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters on EFI models.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 6 months

Subsequent Services:

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

Engine Oil Change Interval:

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

Transmission Oil Change Interval:

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

Primary Chaincase Oil Change Interval:

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

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Drive Belt Inspection:

Inspect at every 5,000 mile service, check tension and condition.

Engine Oil:

Harley-Davidson SYN3 (SAE 20W-50) or equivalent API SG/SH/SJ synthetic motorcycle oil.

Transmission Fluid:

Harley-Davidson Formula + Transmission Lubricant or equivalent SAE 80W-90 API GL-5 gear oil.

Primary Chaincase Fluid:

Harley-Davidson Formula + Transmission Lubricant or equivalent SAE 80W-90 API GL-5 gear oil.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Refer to manual for specific grade and quantity (typically Harley-Davidson Suspension Fork Oil or equivalent).

Common Issues 08 Sportster:

Potential for primary compensator nut loosening (requires Loctite and torque), fuel line leaks (check condition), rear brake master cylinder seal wear, and occasional electrical gremlins associated with sensor failures or wiring harness wear. Some EFI models might require idle relearn procedures.

📚 Vehicle History

Brand History:

Harley-Davidson, founded in 1903, is one of the oldest motorcycle manufacturers in the world, renowned for its V-twin engines and cruiser styling.

Sportster Lineage:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running production model line. The XL1200C represents a modernization of the classic Sportster formula with increased displacement and custom features.

Manufacturing Location:

United States (Various Harley-Davidson facilities)

Key Changes 2008:

For 2008, the Sportster line, including the XL1200C, received electronic fuel injection (EFI) as standard on most models in North America, replacing carburetors for improved emissions and performance consistency. Other updates may include minor styling tweaks and component enhancements.

🏆 Awards & Recognition

Awards:

While specific awards for the 2008 XL1200C are not widely publicized, the Sportster line consistently receives accolades for its iconic status, customization potential, and rider engagement.

Customer Satisfaction:

Generally high customer satisfaction for its segment, particularly among riders who appreciate its classic character and customization options. Reliability is considered good with proper maintenance.