1. Here is a sample of the 2008 Sportster Factory Service Manual

2. The complete 2008 Sportster Service Manual can be found here.


2008 Sportster Maintenance

HARLEY DAVIDSON SERVICE MANUALS 

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Sportster Models

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Service Manual Model Year Application: Harley Davidson XL 883 Sportster (2008), XL 883C Sportster (2008), XL 883L Sportster (2008), XL 1200L Sportster (2008), XL 1200R Sportster (2008), XL 1200N Sportster (2008), Harley Davidson XL 1200C Sportster( 2008), XL 1200C Sportster Custom 105th Anniversary Edition (2008). 08 Harley Custom, 08 Harley Nightster, 08 Roadster, Sportster Low.

Contents of this Harley Davidson Sportster XL Service and Repair Manual: This instant eBook contains fully detailed step-by-step repair procedures with hundreds of high quality photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. This expert text guide book will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures like engine overhaul. Covers every thing you will ever need to know to fix anything on your your 2008 Harley Davidson Sportster XL 883 L, 1200 L, 1200 R, 1200 N, 1200 C Sportster Chopper. Why Pay a mechanic when you can fix your sportster for free.

Here is one chapter (maintenance chapter) of topics covered in this factory service manual. For the full 2008 Harley Sportster service manual and a sneak peak at it see top of the page for details.

MAINTENANCE CHAPTER

1.1 GENERAL................................................................................................................................1-1

1.2 FUEL AND OIL..........................................................................................................................1-5

1.3 MAINTENANCE SCHEDULE....................................................................................................1-7

1.4 BULB REQUIREMENTS.........................................................................................................1-11

1.5 ENGINE OIL AND FILTER......................................................................................................1-12

1.6 BRAKES.................................................................................................................................1-15

1.7 BLEEDING HYDRAULIC BRAKE SYSTEM............................................................................1-17

1.8 TIRES AND WHEELS..............................................................................................................1-20

1.9 PRIMARY CHAIN....................................................................................................................1-23

1.10 CLUTCH...............................................................................................................................1-25

1.11 TRANSMISSION LUBRICANT..............................................................................................1-27

1.12 REAR BELT AND SPROCKETS...........................................................................................1-29

1.13 SHOCK ABSORBER ADJUSTMENT....................................................................................1-31

1.14 REAR BELT DEFLECTION...................................................................................................1-32

1.15 BRAKE PADS AND DISCS...................................................................................................1-36

1.16 BATTERY MAINTENANCE...................................................................................................1-43

1.17 SPARK PLUGS......................................................................................................................1-49

1.18 STEERING HEAD BEARINGS..............................................................................................1-51

1.19 REAR FORK BEARINGS......................................................................................................1-53

1.20 FRONT FORK OIL................................................................................................................1-54

1.21 CABLE AND CHASSIS LUBRICATION.................................................................................1-56

1.22 AIR CLEANER AND EXHAUST SYSTEM............................................................................1-57

1.23 THROTTLE CONTROL.........................................................................................................1-59

1.24 IDLE SPEED AND IGNITION TIMING..................................................................................1-60

1.25 FUEL SUPPLY FILTER..........................................................................................................1-61

1.26 ENGINE MOUNTS AND STABILIZER LINKS.......................................................................1-62

1.27 HEADLAMP ALIGNMENT.....................................................................................................1-63

1.28 FLUID AND LUBRICANT REQUIREMENTS........................................................................1-65

1.29 CRITICAL FASTENERS........................................................................................................1-66

1.30 STORAGE............................................................................................................................1-67

1.31 TROUBLESHOOTING...........................................................................................................1-69

 

 

Perform the service and maintenance operations as

indicated in the regular service interval table. Lack of

regular maintenance at the recommended intervals can

affect the safe operation of your motorcycle, which could

result in death or serious injury. (00010a)

Service operations to be performed before customer delivery

are specified in the applicable model year PREDELIVERY AND

SET-UP MANUAL.

The performance of new motorcycle initial service is required

to keep warranty in force and to ensure proper emissions systems

operation. See

1.3 MAINTENANCE SCHEDULE.

SAFE OPERATING MAINTENANCE

NOTES

•

Do not attempt to retighten engine head bolts. Retightening

•

During the initial break-in period, use only Harley-Davidson

A careful check of certain equipment is necessary after periods

of storage, and frequently between regular service intervals,

to determine if additional maintenance is required.

Check:

1. Tires for abrasions, cuts and correct pressure.

2. Secondary drive belt for proper tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake fluid level and condition. Hydraulic lines and fittings

for leaks. Also, check brake pads and rotors for wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission fluid levels.

7. Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and

turn signal operation.

SHOP PRACTICES

Repair Notes

General maintenance practices are given in this section.

NOTES

•

Repair = Disassembly/Assembly.

•

Replacement = Substitute a new part for existing component.

All special tools and torque values are noted at the point of

use.

All required parts or materials can be found in the appropriate

PARTS CATALOG.

Safety

Safety is always the most important consideration when performing

any job. Be sure you have a complete understanding

of the task to be performed. Use common sense. Use the

proper tools. Protect yourself and bystanders with approved

eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist

whenever necessary. Do not lift heavy parts by hand. A hoist

and adjustable lifting beam or sling are needed to remove some

parts. The lengths of chains or cables from the hoist to the part

should be equal and parallel and should be positioned directly

over the center of the part. Be sure that no obstructions will

interfere with the lifting operation. Never leave a part suspended

in mid-air.

Be sure to check capacity rating and condition of hoists,

slings, chains and cables before use. Exceeding capacity

ratings or using lifting devices that are in poor condition

can lead to an accident, which could result in death or

serious injury. (00466c)

Always use blocking or proper stands to support the part that

has been hoisted. If a part cannot be removed, verify that all

bolts and attaching hardware have been removed. Check to

see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part

to ensure proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and

thoroughly clean the parts before assembly. Keep all dirt out

of parts; the unit will perform better and last longer. Seals, filters

and covers are used in this vehicle to keep out environmental

dirt and dust. These items must be kept in good condition to

ensure satisfactory operation.

When you are instructed in a step to clean fastener threads or

threaded holes, proceed as follows: Clean all LOCTITE material

from fastener threads and threaded holes. Use a wire brush

to clean fastener threads. Use a thread chaser or other suitable

tool to clean threaded holes. Use PJ-1 cleaner or equivalent

to remove all traces of oil and contaminants from threads. Blow

out all threaded holes with low pressure compressed air.

Clean and inspect all parts as they are removed. Be sure all

holes and passages are clean and open. After cleaning, cover

all parts with clean lint-free cloth, paper or other material. Be

sure the part is clean when it is installed.

Always clean around lines or covers before they are removed.

Plug, tape or cap holes and openings to keep out dirt, dust and

debris.

Always verify cleanliness of blind holes before assembly.

Tightening a screw with dirt, water or oil in the hole can cause

castings to crack or break.

20W50 engine oil. Failure to use the recommended oil will

result in improper break-in of the engine cylinders and

piston rings.

can cause engine damage.