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Purpose and scope of the service manual for motorcycle users and technicians.
Guidance on navigating the manual's structure, including table of contents and index.
Safety and preparation guidelines for performing maintenance and repairs.
General notes on service procedures, part quantities, and security system disarming.
Information on periodic service bulletins issued by Harley-Davidson Motor Company.
Emphasis on using genuine Harley-Davidson parts for satisfactory and lasting repairs.
Explanation of safety alert symbols (WARNING, CAUTION) and their significance.
General service, safety, and shop practices for motorcycle maintenance.
Specifications and recommendations for fuel types, gasoline blends, and engine lubrication.
Periodic maintenance requirements for 2008 Sportster models, detailing tasks and intervals.
Chart detailing the required bulbs, their specifications, and Harley-Davidson part numbers.
Procedures for checking, adding, changing engine oil, and replacing the oil filter.
General information, inspection procedures, and troubleshooting for the hydraulic brake system.
Step-by-step procedures for bleeding air from the front and rear hydraulic brake systems.
Information and guidelines for tire selection, inspection, pressure, and wheel compatibility.
Inspection and adjustment procedures for the primary chain.
Clutch adjustment procedures to ensure proper operation.
Information on transmission lubricant type, level checks, and changing procedures.
Inspection and adjustment procedures for the rear drive belt and sprockets.
Procedure for adjusting shock absorber preload for optimal ride.
Inspection and adjustment procedure for rear belt deflection.
Inspection procedures for brake pads and discs, including wear limits.
Procedures for battery maintenance, including charging and connection.
Inspection and maintenance procedures for spark plugs.
Adjustment and lubrication procedures for steering head bearings.
Information and replacement intervals for rear fork bearings.
Procedures for changing front fork oil, including type and amount.
Lubrication procedures for various cables, levers, and chassis components.
Service procedures for the air cleaner and exhaust system, including cleaning and inspection.
Inspection, lubrication, and adjustment procedures for throttle cables.
Procedures for adjusting idle speed and checking ignition timing.
Service procedures for the fuel supply filter, including removal and installation.
Inspection procedures for engine mounts and stabilizer links.
Procedures for aligning the headlamp for proper visibility.
Specifications for all required fluids and lubricants used in the motorcycle.
Identification and importance of critical fasteners in motorcycle assembly and maintenance.
Guidelines for properly storing the motorcycle.
Guide to diagnosing and resolving common maintenance and operation issues.
Technical specifications related to the motorcycle's chassis components.
Information on locating and understanding the Vehicle Identification Number.
Procedures for wheel removal, disassembly, assembly, and installation.
Step-by-step procedure for lacing a 16-inch motorcycle rim.
Step-by-step procedure for lacing a 19-inch motorcycle rim.
Step-by-step procedure for lacing a 21-inch motorcycle rim.
Procedures for truing both lateral and radial aspects of laced wheels.
Methods for checking lateral and radial runout on cast wheels.
Service procedures for the front brake master cylinder assembly.
Service procedures for the front brake caliper, including removal and assembly.
Service procedures for the rear brake master cylinder assembly.
Service procedures for the rear brake master cylinder reservoir.
Service procedures for the rear brake caliper, including disassembly and assembly.
Procedures for removing and installing front and rear brake lines.
Tire removal, installation, cleaning, inspection, and balancing procedures.
Procedures for opening and closing the left side cover.
Service procedures for the front fork, including removal, disassembly, and assembly.
Procedures for the removal, disassembly, and assembly of the fork stem and bracket.
Procedures for removing and installing the belt guard and debris deflector.
Service procedures for the rear fork, including removal, disassembly, and assembly.
Service procedures for shock absorbers, including removal and installation.
Procedures for servicing stabilizer links, including removal and installation.
Procedures for removing and installing the front engine mount/isolator.
Procedures for removing and installing the rear engine mount/isolator.
Procedures for throttle cable removal, disassembly, and installation.
Procedures for clutch control removal, disassembly, and installation.
Procedures for handlebar removal, disassembly, and installation for various models.
Procedures for removing and installing the front fender.
Procedures for rear fender removal and installation for specific models.
Procedures for rear fender and license plate bracket service on XL 1200N.
Procedures for jiffy stand removal, installation, and lubrication.
Procedures for seat removal and installation.
Service procedures for rider foot controls on models with mid-mounts.
Technical specifications for the 2008 Sportster engine.
General information and overview of the engine system.
Information on engine oil pressure, indicator lamp, and checking procedures.
General information regarding the crankcase breathing system.
Guide to diagnosing and resolving common engine performance issues.
Detailed information on the engine lubrication system, including the oil pump.
Guidance on how to navigate and utilize the engine section of the manual.
Procedures for servicing the top end of the engine, both in and out of the chassis.
Procedures for servicing the bottom end of the engine, both in and out of the chassis.
Step-by-step procedure for removing the engine from the motorcycle chassis.
Step-by-step procedure for installing the engine into the motorcycle chassis.
Detailed procedures for disassembling the top end components of the engine.
Detailed procedures for assembling the top end components of the engine.
Detailed procedures for disassembling the bottom end components of the engine.
Detailed procedures for assembling the bottom end components of the engine.
Procedures for valve tappet removal, cleaning, inspection, and installation.
Service procedures for the gearcase cover and cam gears.
Procedures for cylinder head removal, disassembly, cleaning, and installation.
Procedures for cylinder and piston removal, inspection, and installation.
Procedures for crankcase removal, disassembly, and assembly.
Procedures for oil pump removal, disassembly, cleaning, assembly, and installation.
Procedures for oil filter mount removal, disassembly, and installation.
Procedures for oil tank removal and installation.
Technical specifications for the 2008 Sportster fuel system.
Troubleshooting guide for the Electronic Fuel Injection system.
Procedures for air cleaner removal, cleaning, inspection, and installation.
Procedures for fuel tank removal, cleaning, inspection, and installation.
Service procedures for the throttle position sensor.
Service procedures for the engine temperature sensor.
Service procedures for the induction module, including disassembly and assembly.
Service procedures for the idle air control system.
Service procedures for the temperature manifold absolute pressure sensor.
Service procedures for the oxygen sensor.
Procedures for exhaust system removal, installation, and inspection.
Service procedures for fuel injectors, including removal and installation.
Service procedures for the fuel pump, including removal, disassembly, and installation.
Procedure for testing fuel pressure to diagnose system issues.
Procedure for testing the intake system for leaks.
Information on evaporative emissions control systems for California models.
Technical specifications for the 2008 Sportster starter system.
Procedures for starter removal, installation, and testing.
Service procedures for the starter solenoid, including disassembly and assembly.
Technical specifications related to the drive and transmission systems.
Procedure for adjusting the primary chain tension.
Service procedures for the clutch release mechanism.
Service procedures for the primary drive system and clutch assembly.
Procedures for installing and removing the secondary drive belt.
General information and overview of the transmission system.
Procedures for disassembling the engine case for transmission removal.
Detailed procedures for removing and disassembling the transmission.
Detailed procedures for assembling the transmission.
Service procedures for the main drive gear and its bearing.
Service procedures for bearings located in the transmission right case.
Service procedures for bearings located in the transmission left case.
Procedures for installing the transmission into the engine.
Procedures for transmission sprocket removal and installation.
Technical specifications for the motorcycle's electrical system.
Service procedures for the voltage regulator.
Procedures for replacing fuses and relays in the electrical system.
Procedures for replacing the maxi-fuse holder.
Service procedures for single gauge speedometer systems.
Service procedures for dual gauge speedometer and tachometer systems.
Service procedures for speedometer systems on XL 883C and XL 1200C models.
Service procedures for the turn signal and security module.
Procedures for battery cable removal and installation.
Procedures for battery tray removal and installation.
General information and troubleshooting for the ignition system.
Service procedures for the ignition and light switch.
Service procedures for the Electronic Control Module.
Service procedures for spark plug cables.
Service procedures for the ignition coil, including troubleshooting.
Service procedures for the charging system, including alternator and regulator.
Procedures for replacing headlamp bulbs on various models.
Service procedures for indicator lamp modules.
Procedures for tail lamp bulb and base replacement.
Procedures for turn signal bulb and housing replacement.
Service procedures for the license plate lamp module on XL 1200N.
Service procedures for the rear lighting converter module on XL 1200N.
Procedure for replacing the rear stop lamp switch.
Service procedures for the crank position sensor.
Procedures for alternator removal, disassembly, and assembly.
Service procedures for the vehicle speed sensor.
Procedure for replacing the neutral switch.
Procedures for removing and installing the main wiring harness.
Service procedures for electrical caddies and their components.
Service procedures for the jiffy stand switch on international models.
Procedures for optional security siren removal, disassembly, and battery replacement.
Service procedures for the oil pressure switch.
Troubleshooting and replacement procedures for the horn.
Procedures for maxi-fuse removal and installation.
General information and procedures for handlebar switch assemblies.
Service procedures for the right handlebar switch components.
Service procedures for the left handlebar switch components.
Procedures for repairing AMP 1-place electrical connectors.
Procedures for repairing AMP multilock electrical connectors.
Procedures for repairing autofuse electrical connectors.
Procedures for repairing Delphi electrical connectors.
Procedures for repairing the Delphi maxi fuse housing.
Procedures for repairing Deutsch electrical connectors.
Procedures for repairing Deutsch standard terminals.
Procedures for repairing Deutsch solid barrel mini terminals.
Procedures for repairing Deutsch mini terminals.
Procedures for repairing Molex electrical connectors.
Procedures for repairing Packard 150 Metri-Pack connectors.
Procedures for repairing Packard 280 Metri-Pack connectors.
Procedures for repairing Packard 480 Metri-Pack connectors.
Procedures for repairing Packard 630 Metri-Pack connectors.
Procedures for repairing Packard Metri-Pack terminals.
Procedures for repairing Packard ECM connectors.
Procedures for repairing Packard Micro-64 connectors.
Procedures for repairing sealed splice connectors.
Information on connector locations, numbers, and repair instructions.
Information on wiring diagram symbols, color codes, and specific diagrams.
Conversion table for metric measurements.
Conversion tables for various fluid measurements.
Conversion table for torque measurements.
Procedures for compensating sprocket removal, installation, and bearing replacement.
Glossary of acronyms, abbreviations, and definitions used in the manual.
General| Engine Type | Air-cooled, Evolution |
|---|---|
| Fuel System | Electronic Sequential Port Fuel Injection (ESPFI) |
| Transmission | 5-speed |
| Final Drive | Belt |
| Front Brakes | Single disc |
| Rear Brakes | Single disc |
| Displacement | 883cc |
| Bore x Stroke | 76.2 mm x 96.8 mm |
| Compression Ratio | 8.9:1 |
| Front Suspension | 39 mm |
| Front Tire | MH90-21 |
| Rear Tire | 150/80B16 |
| Wheelbase | 60 in. (1525 mm) |
| Seat Height | 668 mm |
| Fuel Capacity | 12.5 L |
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