2008 SPORTSTER SERVICE MANUAL MAINTENANCE & MAINTENANCE INTERVALS GUIDE FOR XL 883 & XL 1200 MODELS

Exact Models Covered in this 2008 Sportster Service Manual:

2008 XL 883 Sportster (XL883)
2008 XL 883C Sportster Custom (XL883C, XL883-C)
2008 XL 883L Sportster Low (XL883L, XL883-L)
2008 XL 1200L Sportster Low (XL1200L, XL1200-L)
2008 XL 1200R Sportster Harley Roadster (XL1200R, XL1200-R)
2008 XL 1200N Sportster Harley Nightster (XL1200N, XL1200-N)
2008 XL 1200C Sportster Harley Custom (XL1200C, XL1200-C)
2008 XL 1200C Sportster Custom 105th Anniversary Edition

2008 Sporster XL 883 & XL 1200 Engine Specifications

Number of cylinders - 2
Type - 4-cycle, 45 degree V-Type, air cooled
Compression ratio - XL883 8.9-1 & XL1200 9.7-1
Displacement - XL 883 - 53.86 cu. 883 cc in.
Displacement - XL 1200 73.20 cu. 1200 cc in.
Torque Specifications 883 55.0 ft-lbs @ 3500 RPM
Torque Specs XL 1200 79.1 ft-lbs @ 4000 RPM

Below is just a sample of contents of the 2008 Harley Davidson HD (H-D) Sportster Xl 883-1200 Maintenance Service Manual, however this manual contains every chapter needed to service, repair or just get a better understanding of your motorcycle.

2008 SPORTSTER MAINTENANCE & MAINTENANCE INTERVAL GUIDE CHAPTERS

General / Fuel And Oil / Maintenance Schedule / Bulb Requirements / Engine Oil And Filter / Brakes / Bleeding Hydraulic Brake System / Tires And Wheels / Primary Chain / Clutch / Transmission Lubricant / Rear Belt Sprockets / Shock Absorber Adjustment / Rear Belt Deflection / Brake Pads And Discs / Battery Maintenance / Spark Plugs / Steering Head Bearings / Rear Fork Bearings / Front Fork Oil / Cable And Chassis Lubrication / Air Cleaner And Exhaust System / Throttle Control / Idle Speed And Ignition Timing / Fuel Supply Filter / Engine Mounts And Stabilizer Links / HeadLamp (Head Light) Alignment / fluid And Lubricant Requriements / Critical Fasteners / Storage / Troubleshooting

OTHER CHAPTERS IN THIS 2008 SPORTSTER SERVICE MANUAL

Table Of Contents / Chassis / Engine / Fuel System / Starter / Electrical / Starter / Drive / Transmission / / Appendix / Wiring / Wiring Diagrams / Tools / Torque Values (Specfications, Specs) / Electrical Diagnostic Manual (See sample download for other chapters included in the electrical diagnostic manual, sample service manual is restricted to one page only.)

2008 SPORTSTER ENGINE

The engine is a two-cylinder, four-cycle, air-cooled, overheadvalve V-twin. It has three major component assemblies: cylinder, crankcase, and gear case. The cylinder assembly includes cylinder head, valves, rocker arm cover, rocker arms, and piston. Cylinders mount on the crankcase in a 45 degree "V", with both connecting rods connected to a single crank pin. The up-and-down motion of the piston in the cylinder is converted to circular motion in the crankcase. The multi-piece crankshaft consists of a crank pin mounted between two counterweighted flywheels, which rotate on two end shaft bearings. The lower end of the rear cylinder connecting rod is forked to fit around the single-end front cylinder connecting rod, allowing a single connecting rod crank pin connection to the flywheel.

The gear case is located on the right side of the crankcase. The gear case houses the gear train which operates and times the valves and ignition. The cam gear train, consisting of four cam shafts with one cam lobe on each shaft, is gear driven. The engine valves are opened and closed through the mechanical linkage of tappets, push rods, and rocker arms. Hydraulic lifters, located in the tappets, automatically compensate for heat expansion to maintain the no-lash fit of valve train components. Tappets serve to transmit the cam action to the valve linkage.Valve timing is obtained by aligning timing marks when installing cam gears. Ignition spark is produced by the operation of a microprocessorcontrolled Electronic Control Module (ECM), ignition coil, and spark plugs. Spark timing is determined primarily by crankshaft rotation, triggering a magnetic sensing unit. Each spark plug fires independently at the end of that cylinder's compression stroke, igniting the air/fuel mixture in the cylinder.

The engine has a force-feed (pressure) type oiling system, incorporating oil feed and return pumps in one pump body, with one check valve on the oil feed side.The feed pump forces oil to the engine, lubricating lower connecting rod bearings, rocker arm bushings, valve stems, valve springs, push rods, and tappets. Cylinder walls, pistons, piston pins, timing gears and bushings, and main bearings are lubricated by oil spray thrown off connecting rods and crankshaft, and by oil draining from each rocker box through an internal drain passage in each cylinder and each tappet guide. Piston jets spray oil on the underside of the pistons to cool the piston crown and skirt area. A small amount of oil is sprayed through an oil galley jet onto the rear intake cam gear in the gear case; oil is transferred to the teeth of all the cam gears by way of the gear meshing action. The oil-scavenging section of the pump returns oil to the tank from the engine.

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.

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.

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when finished. Be sure that everything is done.

Checking Torques on Fasteners with Lock Patches

To check the torque on a fastener that has a lock patch:

1. Set the torque wrench for the lowest setting in the specified torque range.
2. Attempt to tighten fastener to set torque. If fastener does not move and lowest setting is satisfied (torque wrench clicks), then the proper torque has been maintained.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding specified torque. Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable tap or die. Replace all damaged or missing lubrication fittings. Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT on pipe fitting threads.

Wiring, Hoses and Lines

Hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications.

Instruments and Gauges

Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is difficult.

FUEL AND OIL FUEL

Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump. Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making air entrapment and pressurization a possibility. Refer to your service manual for exact recomended gas, gasoline & whic octane rating to use.

GASOLINE BLENDS

Your motorcycle was designed to get the best performance and efficiency using unleaded gasoline. Most gasoline is blended with alcohol and/or ether to create oxygenated blends. The type and amount of alcohol or ether added to the fuel is important.

• Gasoline containing METHYL TERTIARY BUTYL ETHER (MTBE): Gasoline/MTBE blends are a mixture of gasoline and as much as 15% MTBE. Gasoline/MTBE blends can be used in your motorcycle.

• ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%.

• REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline, leaving fewer tailpipe emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible, as an aid to cleaner air in our environment.

• Do not use race gas or octane boosters. Use of these fuels will damage the fuel system.

Some gasoline blends might adversely affect the starting, driveability or fuel efficiency of the motorcycle. If any of these problems are experienced, try a different brand of gasoline or gasoline with a higher octane blend.

ENGINE LUBRICATION

2008 Sportster Engine Oil

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life of the engine. Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil change. Refer to service manual. Your authorized dealer has the proper oil to suit your requirements. If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4. The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and 10W40.

Sportster Engine Oils

Refer to service manual for correct engine oil specifications for your sportster.

SAE 10W40 HD
SAE 20W50 HD
SAE 50 HD 
Heavy SAE 60

In colder climates, the engine oil should be changed often. If motorcycle is used frequently for short trips, less than 15 miles (24 kilometers), in ambient temperatures below 60° F (16° C), oil change intervals should be reduced. Motorcycles used only for short runs must have a thorough tank flush-out before new oil is put in.

MAINTENANCE SCHEDULE

The maintenance table in the service manual lists the periodic maintenance requirements for Sportster model motorcycles. If you are familiar with the
procedures, just refer to the table in the service manual for the recommended service interval. If necessary, also available in the service manual is a quick reference 2008 sporster maintenance interval table for the required specifications. If more detailed information is needed, turn to the sections
which follow for step-by-step instructions. Also, throughout the manual, you will be instructed to use various lubricants, greases and sealants. for the correct part numbers of these items.

Many parts need to be maintained at specific mile points for excellent performance, saftey and reliablility. The maintenance intreval chart give detail information on if which part need service, repalacement, cleaning, lubrication or inspections @ 30,000, 25,000, 20,000, 15,000, 10,000, 5000 & 1000 mile, miles interval.

Example of parts typically found in a 2008 Sportster XL 883, 1200 maintenance interval chart:

Engine oil and filter
Oil lines and brake system
Air cleaner Inspect
Tires Check pressure
Wheel spokes
Transmission lubricant
Clutch 
Primary chain
Rear belt and sprockets
Throttle, brake and clutch controls
Jiffy stand
Fuel lines and fittings
Fuel tank filter screen
Brake fluid
Brake pads and discs
Front brake lever pin
Lubricate
Brake caliper pins
Brake caliper boots and bushings
Rear master cylinder outer boot
Master cylinders and calipers
Brake components
Master cylinder pistons
Spark plugs
Electrical equipment and switches
Engine idle speed
Front fork oil
Steering head bearings
Rear fork bearings
Shock absorbers
Critical fasteners
Engine mounts and stabilizer links
Battery
Exhaust system

ENGINE OIL AND FILTER - CHECKING AND ADDING OIL

Check engine oil level in oil tank and add oil if necessary. Oil tank capacity (wet) is (see service manual) quarts - liters. Refer to service manual for recommended engine oil viscosity.

Removing and Replacing Oil Filler Cap
Checking Oil with Cold Engine
Checking Oil with Warm Engine

CHANGING OIL AND FILTER

Removing Oil Filter
Draining Oil Tank
Installing New Oil Filter

BRAKES - GENERAL / NSPECTION / TROUBLESHOOTING

The front and rear brakes are fully hydraulic disc brake systems that require little maintenance. The front brake master cylinder is an integral part of the brake hand lever assembly on the right handlebar. The rear brake master cylinder is located at the rear of the motorcycle's frame, beneath the rear fork pivot point and is actuated by the rear brake pedal via mechanical linkage.

Bleeding Front Brake
Bleeding Rear Brake

1. Front brake master cylinder and reservoir
2. Cover screw
3. Top cover
1. Front brake master cylinder assembly
2. Diaphragm
3. Diaphragm plate
4. Reservoir cover
1. Rear brake master cylinder reservoir
2. Reservoir cap
3. Upper fluid level
4. Lower fluid level
5. Reservoir cover
1. Rear brake caliper
2. Bleeder valve
3. Bleeder cap
5. Captive screw

TIRES AND WHEELS

Tires - Dunlop Harley-Davidson tires
Tire Pressure
Checking Tire Pressure & Tread
Tire Replacement
When to Replace Tires
Tire Inspection
Wheel Bearings
Wheel Spokes
Primary Chain Inspection & Adjustment
Clutch Adjustment

1. Screw (6)
2. Clutch inspection cover
3. Hex lockplate and spring
4. Nut
5. Ramp assembly
6. Coupling
7. Quad ring
8. Clutch adjusting screw assembly
9. Primary cover
1. Clutch cable
2. Cable ferrule
3. Clutch lever bracket
4. Adjustment range

TRANSMISSION LUBRICATION: SPORTSTER MODELS

Check Lubricant Level & Changine Lubricant
1. Drain plug
2. Clutch inspection cover
3. Screw (6)

1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Quad ring
4. Primary cover
5. Chaincase lubricant level

REAR BELT AND SPROCKETS

Inspection & Cleaning

Sprockets
Rear Belt