🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL 1200R Sportster 1200 Roadster

Year:

2008

Engine Family:

Evolution

Model Code:

XL1200R

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops.

Comparison Points:

Harley-Davidson's Sportster line is a staple, offering a balance of performance and classic styling. The Roadster variant emphasizes a sportier riding posture and dual front disc brakes compared to other Sportster models of the era.

Vehicle Focus:

The XL 1200R Roadster is known for its potent Evolution engine, classic styling, and capable handling, making it a popular choice for customizers and everyday riders.

Manual Value Proposition:

Empowers owners with factory-level information to maintain, repair, and troubleshoot their motorcycle efficiently, saving time and money on dealership visits.

📋 Manual Details

Primary Coverage:

Comprehensive service and repair

Specific Systems:

Engine, transmission, chassis, electrical, fuel, ignition, brakes, suspension, bodywork, troubleshooting

Estimated Pages:

Over 600

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed breakdown of Evolution V-Twin engine, including cylinder heads, pistons, crankshaft, camshafts, valve train, oil pump, timing.

Fuel And Carburetion:

Carburetor (Keihin CV) overhaul, adjustment, fuel tank, fuel lines, fuel pump operation.

Ignition System:

Ignition module, spark plugs, ignition coils, timing adjustments.

Transmission And Drivetrain:

5-speed transmission disassembly, assembly, gear inspection, clutch operation, primary drive, final drive belt maintenance.

Electrical System:

Wiring diagrams, charging system (alternator, stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, battery maintenance.

Brakes:

Hydraulic brake system diagnosis, front and rear caliper service, master cylinder overhaul, brake fluid replacement, rotor inspection.

Suspension And Steering:

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

Chassis And Frame:

Frame inspection, swingarm pivot, wheel bearing service, spoke tensioning (if applicable).

Bodywork And Fittings:

Fender removal/installation, fuel tank mounting, seat adjustments, exhaust system removal/installation.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, chain/belt adjustment (if applicable), brake checks, tire pressure.

Troubleshooting:

Diagnostic charts for common symptoms, electrical fault finding, engine performance issues.

Disassembly And Assembly:

Step-by-step instructions for major component removal and reinstallation.

Rebuilds:

Detailed procedures for engine, transmission, and brake caliper rebuilds.

Adjustments:

Carburetor, clutch, throttle cables, brakes, suspension.

Depth:

Comprehensive (from basic checks to full engine rebuilds).

Diagnostics:

Includes diagnostic procedures and symptom-based troubleshooting guides.

Specifications:

Detailed torque specifications, clearances, fluid capacities, electrical resistance values.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text for quick information retrieval.

Image Resolution:

High-resolution for clear diagrams and illustrations.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.4 cubic inches)

Bore X Stroke:

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

Compression Ratio:

9.0:1

Valve Train:

Overhead valves (OHV), pushrod-actuated, 2 valves per cylinder

Horsepower Est:

Approximately 65-70 hp (at crankshaft)

Torque Est:

Approximately 70-75 ft-lbs (at crankshaft)

Fuel Delivery:

Keihin CV (Constant Velocity) carburetor, 40mm

Fuel Tank Capacity:

3.1 gallons (11.7 L)

Oil Capacity:

3.0 US qt (2.8 L) with filter change

Oil Type Spec:

Harley-Davidson recommends SAE 20W50 SYN3 or equivalent motorcycle oil meeting Harley-Davidson specifications.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Primary Drive:

Duplex chain, 1.373:1 ratio

Final Drive:

Belt, 2.75:1 ratio

Gear Ratios:

1st: 10.110, 2nd: 6.905, 3rd: 4.947, 4th: 3.814, 5th: 3.179

Transmission Fluid Type:

Harley-Davidson recommends Harley-Davidson Formula+ transmission lubricant or equivalent.

📐 Dimensions

Length:

87.4 in. (2220 mm)

Width:

32.9 in. (835 mm)

Height:

46.7 in. (1186 mm)

Seat Height Laden:

28.1 in. (714 mm)

Dry Weight:

554 lbs (251 kg)

Gross Vehicle Weight Rating:

900 lbs (408 kg)

Front Tire:

100/90-19 57H

Rear Tire:

150/80-16 71H

Wheelbase:

60.0 in. (1525 mm)

🛡️ Safety Features

Crash Test Data:

Motorcycles are not typically subjected to standardized crash testing like automobiles.

Brakes:

Dual front hydraulic disc brakes, single rear hydraulic disc brake. Excellent stopping power for its class.

Suspension:

Telescopic front fork with 4.1 in. travel, rear swingarm with coil-over shock absorbers with adjustable preload and 3.0 in. travel, contributing to stable handling.

Lighting:

Halogen headlamp, taillight, and brake lights for visibility.

💡 Technology Features

Audio System:

Not typically equipped with integrated audio systems from the factory on the Roadster model. Aftermarket options are common.

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, and indicator lights. Limited electronic features.

ABS:

Anti-lock Braking System (ABS) was an optional feature for 2008 models. Check specific vehicle VIN for confirmation.

Connectivity Features:

No integrated Bluetooth or smart device connectivity from the factory.

🔧 Maintenance

First Service:

Recommended at 1,000 miles (1600 km) or 6 months, whichever comes first.

Subsequent Service:

Generally every 5,000 miles (8,000 km) or 12 months for regular maintenance, with more detailed checks at higher mileage intervals.

Engine Oil Type:

SAE 20W50 motorcycle oil (Harley-Davidson SYN3 or equivalent)

Transmission Oil Type:

Harley-Davidson Formula+ or equivalent

Primary Chain Case Oil Type:

Harley-Davidson Formula+ or equivalent

Brake Fluid Type:

DOT 4

Common Wear Items:

Clutch plates, drive belts (if showing signs of wear/cracking), brake pads, fork seals, battery terminals.

Potential Issues 2008:

Early model years of the fuel-injected Sportsters sometimes experienced regulator/rectifier issues, though the 2008 models were generally improved. Carburetor tuning can be sensitive. Proper battery maintenance is crucial for starting reliability.

Oil Filter Example:

Harley-Davidson part numbers vary, but a common aftermarket equivalent for this era is often found under brands like K&N (e.g., KN-170) or Wix.

Air Filter Example:

Stock Harley-Davidson part numbers or common aftermarket equivalents such as Screamin' Eagle or K&N.

📚 Vehicle History

Foundation:

Harley-Davidson Motor Company, founded in 1903, is an iconic American motorcycle manufacturer.

Sportster Line:

The Sportster line, introduced in 1957, has been a cornerstone of Harley-Davidson's lineup, evolving from a lightweight sport bike to a versatile cruiser. The XL 1200R Roadster variant represents a performance-oriented iteration within the modern Sportster family.

Production Era:

The XL 1200R was a specific model designation for certain model years, with the 2008 model year being part of the evolution of the 1200cc Sportster offerings.

🏆 Awards & Recognition

Model Specific Awards:

While specific awards for the 2008 XL 1200R are not widely documented, the Sportster line consistently receives praise for its classic styling, V-twin character, and customization potential from automotive and motorcycle media.

Owner Satisfaction:

Generally high owner satisfaction for the Sportster platform due to its iconic status and mechanical simplicity, when properly maintained.