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2008 Sportster Models Service Manual

Contents

1. D 1 Sprocket Bearing Replacement usssusss D 1 p erri cues c m D 1 LTC TT E REO DO D 2 Assembly and Installation eese D 2 APPENDIX E GLOSSARY E 1 GLOSSARY Acronyms and Abbreviatloris ucucc eere eere tetti ies E 1 REFERENCE MATERIAL TOOLS l TORQUE VALLES iissstisnnsssenndnnnsecnsscnsnsainnins Vil INDE Mem MET TP XXI SUBJECT PAGE NO 1 2 FUEL AND OIL 1 3 MAINTENANCE SCHE 1 4 BULB REQUIREMENTS 1 5 ENGINE OIL AND FILTER id A aad i To BARES aspire cames a iat ied oie 7 LN BLEEDING HYDRAULIC BRAKE SYSTEM 1 1 1 8 TIRES AND WHEELS Saioan ee en eee panacea ida icio abeat eiii aam TO 1 9 PANAN CHAIN 1 1 LT TRANSMISSION LUBRICANT AEE E E 1 12 REAR BELT AND SPROGNKETS ico nmt eencos e m 1 18 SHOCK ABSORBER ADJUSTMENT 1 31 1 14 REAR BELT DEFLECTION 1 32 1 15 BRAKE PADS AND DISCS si E T iii a d B 1 16 BATTERY MAINTENANCE 1 43 137 SPARK PLUGS tritici 1 49 1 18 STEERING HEAD BEARINGS 1 51 1 19 REAR FORK BEARINGS POART 1 53 1 20 FRONT FORK OIL 1 54 1 21 CABLE AND CHASSIS LUBRICATION N e 1 22 AIR CLEANER AND EXHAUST SYSTEM 57 1 23 THROTTLE CONTRO Lcon 1 24 IDLE SPEED AND IGNITION TIMING 1 25 FUEL SUPPLY FILTER iis f sd ed a eae EPIO UU Y aaa eae na ees E 1 26 ENGINE MOUNTS AND STABILIZER INKS
2. A 28 Installing Socket Terminal A 28 A 15 PACKARD METRI PACK TERMINALS Metri Pack Terminal Crimps esses A 29 Matching Terminal To Crimper A 29 Preparing Wie EOS uisi usu idenen it ois tsp cic ob eade A 29 CIF Wiig ONE Lisa Eck ERG Eoo cisco A 29 Crimping Insulauon Segl uac soris terea A 29 inspecting OI ccadedec eui AREA IE C ad ere ax A 30 A 16 PACKARD ECM CONNECTOR Packard 100W Connector Repair s A 31 cll A 31 Separating Socket Housing From EOCM A 31 Mating Socket Housing To ECM A 31 Removing Socket Terminal A 31 Installing Socket Terminal A 31 Drimplig Tet TANS essasi snis tte A 31 A 17 PACKARD MICRO 64 CONNECTORS Packard Micro 64 Connector Repair A 33 CODI ned ibd iri pi dla A 33 Separating Pin and Socket Housings A 33 Mating Pin and Socket Housings A 33 Removing Termllial sceresecrine ptus tton err roster A 33 installing Terminal sees ie rir prry rator et reri Ree A 33 Preparing Wire Leads for Crimping A 34 CGI VERMIN S sc uus prim ap Sid Lo dab va dos nERUP iban A 34 Inspectitg Gimpa veo oio k eor ehe Fri rr En R AED A
3. For brake line replacement procedures see 2 14 BRAKE LINES TROUBLESHOOTING Use the following troubleshooting guide to help in determining probable causes of poor brake operation 2008 Sportster Service Maintenance 1 15 Table 1 7 Troubleshooting Brakes CONDITION CHECK FOR REMEDY Excessive lever or pedal travel or spongy feel Air in system Master cylinder reservoir low on fluid Bleed brake system Fill master cylinder reservoir with approved brake fluid Bleed brake system Chattering sound when brake is applied Worn brake pads Loose mounting bolts Warped brake disc Replace brake pads Tighten bolts Replace brake disc Ineffective brake lever or pedal travels to limit Low fluid level Piston cup not functioning Fill master cylinder reservoir with approved brake fluid and bleed brake system Rebuild master cylinder Ineffective brake lever or pedal travel normal Distorted or glazed brake disc Distorted glazed or contaminated brake pads Replace brake disc Replace brake pads Brake pads drag on disc will not retract Cup in master cylinder not uncovering relief port Inspect master cylinder 1 16 2008 Sportster Service Maintenance BLEEDING HYDRAULIC BRAKE SYSTEM 1 7 GENERAL Bleed the hydraulic brake system any time a hydraulic brake line brake master cylinder or brake caliper has been opened o
4. ssssss 2 64 Lubricating Rear Caliper Bolt Pins and Boots 2 64 Diog MTS 2 65 TES TAU t e 2 66 2 14 BRAKE LINES giri MB os cee sect cnc ataesiravatiacenl adespenrduewceiananaedan 2 68 Fa MIA Passe 2 68 STAN AU GN P 2 69 xi ig 48 rr 2 70 PAB IMOV c 2 70 girl AMON e mE 2 71 2 15 TIRES c r e M n 2 72 Gli 2 e en 2 72 Cleaning Inspection and Repair s 2 72 n zziz cipe T trt E 2 73 WES Ype TMo Skrsi 2 73 Tubeless Tre em 2 73 Checking Tire PUCIDUL uuo rcr rre tri opea 2 74 Eri cjr m 2 74 Radial RUNOUE essensies a 2 74 wheel Balancing sissen 2 74 Weights for Laced Wheels sss 2 74 Weights for Cast WHEE sicsccussesccctsteisctacssntsrasessbionces 2 75 2 16 LEFT SIDE COVER c r A 2 76 Opening Lent Side COVBL a eiasie bna Midi iat Ee R ka E ERU 2 76 Glosing Lo SIGS COll anniina 2 77 Removing Left Side Cover sessesss 2 77 Installing Lett Side Covel essc rie rra rtr piter rra rr hene 2 77 2 17 FRONT FORK ENE Tell M 2 78 PROTO AN ee 2 78 BISE a a SEE E N A E 2 78 Cleaning Inspection and Repair s 2 80 BOSE csi e RA EEG A ERU ave 2 80 TABLE OF CONTENTS V TABLE OF CONTENTS SAN OP ii ccticincsascepiceriatatoomnsetincedieeranmtcenstasmarintate 2 81 2 18 F
5. RX 1 69 Starts But Runs Irregularly or Misses 1 69 Spark Plug Fouls Repeatedly 1 70 Pre Ignition or Detonation Knocks or Pings 1 70 Check Engine Light Illuminates During Operation 1 70 BU cii ome 1 70 yale marn NOSE 1 70 Excessive VDANO iine 1 70 LIAL SYSTE irsana aestas 1 70 Oil Does Not Return To Qil Tank 1 70 Engine Uses Too Much Oil Or Smokes Excessively 1 70 Engine Leaks Oil From Cases Push Rods Hoses creme PE E RET 1 70 Law Ol PRS SUS cee es ER 1 70 High OU PSS SINS ocn prie ER dr oU FAMAE T PUR Mis 1 71 Electrical SYSIBITI i sereno Fr rxE or ERR EHI I UFU CIE FEL Pe Rr 1 71 Alternator Does Not Charge ss 1 71 Alternator Charge Rate Is Below Normal 1 71 Speedometer Operates Erratically 1 71 TERES BIN qutzia s cca E E A E EE EEEE 1 71 SNS HAAN eT 1 71 Junps Qut OT GRAM ariasi 1 71 pero earan 1 71 Clutch Drags Or Does Not Release 1 71 Glutei Crane eo eee eee er eer HEROS pit tern err ee 1 71 wipe P caida E TE 1 71 BAS a casdeiie locdes 1 71 Brake Does Not Hold Normally 1 71 CHASSIS 2 1 SPECIFICATIONS 2008 Sportster Specifications ssssss 2 1 lj 2 2 2 2 VEHICLE IDENTIFICATION NUMBER
6. A 23 A 11 PACKARD 150 METRI PACK CONNECTORS 150 Metri Pack Connector Repair A 24 c cup MM TR A 24 Separating Pin and Socket Housings A 24 Mating Pin and Socket Housings A 24 Removing Socket Terminal A 24 Inserting Socket Terminal s A 24 A 12 PACKARD 280 METRI PACK RELAY AND FUSE BLOCK CONNECTORS Bi 2E 4X1 p p A 26 Removing Socket Terminals A 26 Installing Socket Terminals A 26 TABLE OF CONTENTS Grimpa Tertilfisle uucuncade mae tercscia etos cte tine A 26 A 13 PACKARD 480 METRI PACK CONNECTORS 480 Metri Pack Connector Repair essss A 27 CE CVA S esc PPAR RA E rd E Ee Ib died REDE A 27 Separating Pin and Socket Housings A 27 Mating Pin and Socket Housings A 27 Removing Socket Terminals A 27 Installing Socket Terminals A 27 A 14 PACKARD 630 METRI PACK CONNECTORS 630 Metri Pack Connector Repair ss A 28 EEUE r E E E TE A 28 Separating Pin and Socket Housings A 28 Mating Pin and Socket Housings A 28 Removing Socket Terminal
7. GENERAL 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 WARNING Use denatured alcohol to clean brake system components Do not use mineral based solvents such as gasoline or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a P Yel XVIe Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a CAUTION D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b NOTES If D O T 4 brake fluid contacts painted surfaces IMMEDI ATELY flush area with clear water Cover
8. esesss 3 22 3 10 REMOVING ENGINE FROM CHASSIS PAESI cai aside ba A Ode eoe E E E EA EL EE d 3 23 dier ojo Mee c 3 23 3 11 INSTALLING ENGINE IN CHASSIS lc m M 3 28 Proce dTe ee ET 3 28 3 12 TOP END OVERHAUL DISASSEMBLY tol E 3 31 Stripping Motorcycle for Top End Repair 3 31 eg sixcsesctsceceesscesaiamiieiimacinipctnmuean 3 32 Disassembling Rocker Covers 3 32 Removing Cylinder Heat caet 3 34 Disassembling Push Rods and Covers 3 36 Cylinder ang PISIS iie ne 3 37 3 13 TOP END OVERHAUL ASSEMBLY c ne 3 39 Pelon and CYNE eei ut Pro suede ERR a 3 39 Push Rods Covers and Retainers 3 40 uUls Hi ss a satecitapereience eceatiilcaertenelieeetidaunoanmien 3 42 aue cars TEMPUS 3 45 Assembling Motorcycle After Top End Repair 3 47 3 14 BOTTOM END OVERHAUL DISASSEMBLY o r 3 48 it C 3 48 e NU M 3 48 Gearcase Cover and Cam Gears sess 3 48 perg cc neha 3 49 Removing Piston Oil Jets sess 3 51 Removing Cylinder Base Studs 3 51 3 15 BOTTOM END OVERHAUL ASSEMBLY jul dero E C H 3 52 installing Piston Ol Jefe nitet rane 3 52 Installing Pinion Sh
9. 1 62 1 27 HEADLAMP ALIGNMENT 1 63 1 28 FLUID AND LUBRICANT REQUIREMENTS s169 1 28 CRITICAL EASTENERS iati marin 1 66 1 30 STOPINGIES stipes T 1367 1 31 TROUBLESHOOTING NOTES GENERAL 1 1 SERVICING A NEW MOTORCYCLE WARNING 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 sys tems operation See 1 3 MAINTENANCE SCHEDULE SAFE OPERATING MAINTENANCE NOTES Donotattemptto retighten engine head bolts Retightening can cause engine damage During the initial break in period use only Harley Davidson 20W50 engine oil Failure to use the recommended oil will result in improper break in of the engine cylinders and piston rings 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 p
10. 6 44 Shift Drum BUSHING acces casn rine RS e R2 6 44 6 13 TRANSMISSION INSTALLATION BIO caros od Ee EE Lucie tte c E Shifter Forks and Drum Assembly Assembling Crankcases Shifter Shaft Inatallatiol cite oni corti tad rape eret te cR orta 6 14 TRANSMISSION SPROCKET Rena Mm 6 50 MS LANA CIUS TR ENTER IT TE EE TO T Do 6 51 ELECTRICAL 7 1 SPECIFICATIONS ELECTRICAL Specifications 2008 Sportster Models 7 1 7 2 VOLTAGE REGULATOR BOE erre E A AE ero tendo rident edere 7 2 PROMOVA e e 7 2 NS PATRIS Hu coi esa atu dara ETT E sh aa E E EE Ansa E 7 8 7 3 FUSES AND RELAYS EE r E ORE ET 7 5 Replacing FUsBS issire cemere ripe n HI pA Re e te 7 5 Replacmg PIBIBVS ou arat etidio Festo Medo ru Pr Ie S PRAU IAE v dR DU NERE abs 7 5 7 4 MAXI FUSE HOLDER C M 7 6 re ieee IO aisa S 7 6 7 5 SPEEDOMETER ALL SINGLE GAUGE MODELS EXCEPT XL 883C XL 1200C ELLIOTT T TT TT 7 7 SSO TT TO EOS 7 7 7 6 SPEEDOMETER AND TACHOMETER ALL DUAL GAUGE MODELS Speedometer Removal senes 7 9 Trip Odometer Reset Switch Replacement 7 9 tachometer Removal s nis raatio eina ari p pL Ses ua ti rrins 7 9 Speedometer Installation sees 7 10 Tachometer Installation rina ei na 7 11 7 7 SPEEDOMETER XL 883C XL 1200C RENO EEL Le pa cte ERE EEM
11. Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making air entrapment and pressur ization a possibility Table 1 1 Octane Ratings SPECIFICATION Pump Octane R M 2 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 CAUTION Do not use gasoline that contains methanol Doing so can result in fuel system component failure engine damage and or equipment malfunction 00148a Gasoline containing METHYL TERTIARY BUTYL ETHER MTBE Gasoline MTBE blends are a mixture of gasoline RATING 91 95 RON 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 1096 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
12. Bleeder cap Figure 1 15 Rear Brake Caliper 2008 Sportster Service Maintenance 1 19 TIRES AND WHEELS 1 8 TIRES WARNING Match tires tubes air valves and caps to the correct wheel rim Contact a Harley Davidson dealer Mismatching can result in damage to the tire bead allow tire slippage on the rim or cause tire failure which could result in death or serious injury 00023a WARNING Use only Harley Davidson approved tires See a Harley Davidson dealer Using non approved tires can adversely affect stability which could result in death or serious injury 00024a WARNING Use inner tubes on laced wire spoked wheels Using tubeless tires on laced wheels can cause air leaks which could result in death or serious injury 00025a NOTES Inner tubes must not be used in radial tires and radial tires must not be used on laced wire spoked wheels Tubeless tires are used on all Harley Davidson cast and disc wheels Tire sizes are molded on the tire sidewall See Table 1 8 Inner tube sizes are printed on the tube New tires should be stored on a horizontal tire rack Avoid stacking new tires in a vertical stack The weight of the stack compresses the tires and closes down the beads Check tire pressure and tread As part of the pre ride inspection At every scheduled service interval 1 2 Inspect each tire for punctures cuts and breaks Inspect each tire for wear Replace tire
13. Inspection and Repair sssse 2 98 Assembly and Installation eeeeeeeeeess 2 99 2 26 CLUTCH CONTROL ORSON EIN isa o PIA en dR DAMM IM MERIC 2 100 Removal and Disassembly sess 2 100 Clutch Cable Lower 2 100 Clutch Lever and Clutch Cable Upper 2 101 VI TABLE OF CONTENTS Guten Bare CODO renint 2 101 Assembly and Installation esterni 2 102 Gutek Rand CONTR iiis Dici Dd reete dadmcicue 2 102 Clutch Lever and Clutch Cable Upper 2 103 Cl teh Cable LOWER casieria 2 103 MULA RERO ER CER C DNE De E 2 103 2 27 HANDLEBARS PROB S setis Eta vv chap ba br MER liv EIE 2 104 BINOS S cecileieiitrck con but Dd Hd aut dct RE Edid cadat 2 104 XI DESC ad XL 12006 ciinei 2 104 AL 1T200L ang XL 1200N ioee cei rette 2 105 All Except XL 883C XL 1200C XL 1200L and XL TON acurisxietivecidenieg ce ains e rv pis xax cO Feb eb dad a 2 106 STAN MON mE D OC o D D 2 107 AL 8836 and XL TEOUG reo e ipei Ee rtp ees 2 107 XL 1200L and XL 1200N ueteres 2 108 All Except XL 883C XL 1200C XL 1200L and XL psc p M 2 108 RID ROBHBIS s rest rm petas tdem 2 109 2 28 FRONT FENDER Pals OVE Ne e setae is cna E Case Docendi Cb dco dpi ped a ton 2 110 FRE RI as decet eb GR ER Bd ecce n n HE 2 110 Mire ABO aac iod cn recede buz ip aa aee gla doa 2 110 2 29 REAR FENDER ALL MODELS EXCEPT XL 1200N Genera MERECE E
14. Removal sissen NETE 7 88 POSES SON NINN enan e EAS ES 7 88 Switch Repair Replacement seeseseese 7 88 Upper Housing PBDSII iuste reyes 7 88 Lower Housing Repi uiui ec aa scene atssetancesesenanaden 7 89 Tur Eett Signal Swe ec cu cesi cii eice ito omicidio 7 89 Gluteh Interlock SWC ia uii ii diria rrt dee Rina 7 89 5 c gps ye 7 89 lias TANGO Gy anaia 7 90 APPENDIX A CONNECTOR REPAIR A 1 AMP 1 PLACE CONNECTORS AMP 1 Place Connector Repair esessss A 1 CRIME eee enira P E Ub ders A 1 Separating Pin and Socket Housings A 1 Mating Pin and Socket Housings A 1 Removing Socket Terminals A 1 Installing Socket Termltigl accesserat cric A 1 Removing Pii TEMNA e A 1 Installing Pin Termirislla eie reir riter tte A 2 A 2 AMP MULTILOCK CONNECTORS AMP Multilock Connector Repair esses A 3 co pee P HT A 3 Separating Pin and Socket Housings A 3 Mating Pin and Socket Housings A 3 Removing Terminals from Housing A 3 Inserting Terminals into Housing A 4 Preparing Wire Leads for Crimping A 4 Grimping Terminals to Leads actores A 5 Inspecting Crimped Terminals A 6 A 3 AU
15. XL 1200L and XL 1200N 7 34 Replacement XL 883C and XL 12000C 7 35 Replacement All Other Models ssss 7 35 Reassembling Vehicle All Models 7 36 TABLE OF CONTENTS 7 19 TAIL LAMP ALL MODELS EXCEPT XL 1200N c r T E E A 7 37 iWon e Lm 7 97 Base nicer qp e 7 97 7 20 TURN SIGNALS cr 7 40 Bulb Replacement eee ceteri rito rry eris dtp e Pts 7 40 Front Housing Replacement enn 7 40 Rear Housing Replacement c ccescceeseseeesereeneee 7 41 Preliminary Vehicle Disassembly All Models 7 41 Disconnect Wiring All Models Except XL 1200N 7 41 Disconnect Wiring XL 1200N esceeeseeeeesereeeeee 7 42 Remove and Disassemble Turn Signal Assembly All oa T 3 Reassemble and Install Turn Signal Assembly All FS E PE AA E E T acaatnentie 7 44 Connect Wiring All Models Except XL 1200N 7 45 Connect Wiring XL 1200 deem 7 45 Final Assembly All Models essss 7 45 7 21 LICENSE PLATE LAMP MODULE XL 1200N ccr 7 46 Removal Domestic Only sies iiem et ape Sab PA MEER IS pP d RUN nd 7 46 Installation Domestic Only nre enne 7 46 Removal MDI OMIY isc c ecutipun costa p iara ote oEz Foqp eis eia a cioe 7 47 Installation AB OY ara to sica ea ita a
16. 34 A 18 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair A 36 tur T A 36 Preparing Wire Ease us oideieciege uai cia eirca A 36 sevi BSc RN A 36 lrrspecing SESS sido e p HEP NIRE Ep EID PEM DUE A 36 APPENDIX B WIRING B 1 CONNECTORS Connector 6800116 ie decsceiieciicee eiat eb erbe xb brine ia B 1 Funcion Locatii oca recede rH EHE EE FU espe Eie DRE S B 1 TABLE OF CONTENTS XIII TABLE OF CONTENTS Place and QelQlkssucizasteenteido etie tuprtcut zrtab a ac seo ie aca B 1 Gohnector fNUITbel iussus era esca Eoi E EE ata B 1 Repair rz gd err io es necctnczecaitaciecieanstraecaeeenateoneuds B 1 B 2 WIRING DIAGRAMS Wiring Diagram Information eeeeenne B 3 birgczecqeo cp B 3 Wiring Diagram Symbols erts B 3 2008 Sportster Wiring Diagrams ssesss B 4 APPENDIX C CONVERSIONS C 1 METRIC CONVERSION Conte SIO A EE NETTE A C 1 C 2 FLUID CONVERSIONS United States Systeri i C 2 Mete Susp uus roses SER FEUINR OR SEE HUM PERRA RE SERREAU C 2 British Imperial Systemisk C 2 C 3 TORQUE CONVERSIONS United States SYSIOITL uaiiceczrescbrcotete ou eua ta securo rais C 3 ISG VERD n de bdo M EERAELE EAR EE T a MAG ERAUA C 3 XIV TABLE OF CONTENTS APPENDIX D COMPENSATING SPROCKET D 1 COMPENSATING SPROCKET MSI All t D 1 Removal and Disassembly iia nna nas D 1 Cleaning Inspection and Repair
17. V I N Vehicle Identification Number V I N Sportster Models 2 4 E All T T 2 4 Bbbreviated V LIN us assa endis nx ier b inn nad las eda 2 4 2 3 WHEELS EMI ENERO UE 2 6 Miefer imein me 2 6 uei ETE I TT 2 7 PTT eO UR P persis 2 7 Disassembly Cast Front Wheel s 2 7 Disassembly Laced Front Wheel 2 8 Cleaning and Inepebtlontu si ee encantan ces 2 8 Assembly Cast Front Wheel seessss 2 8 Assembly Laced Front Whbegl reas 2 8 nare ETU y AEE sew e de RA ERU E bb ek FERE E RP err ter A naut EU E 2 12 Raai Whea ecricirs ar 2 12 Pemoval sosna MEN ERED adit AP DERE IU 2 12 Disassembly 2 13 Cleaning and Inspeotiph s cernerent nnn 2 13 Lippe e 2 13 Eti 2 16 Sealed Wheel Bearings eee 2 16 InSpoc HON ecco E ciii deis tur o Zune bord etia cade 2 16 REMOVA e 2 17 lucir m 2 19 2 4 WHEEL LACING 16 INCH RIM LI 2 20 PROC COUNGS eR m 2 20 2 5 WHEEL LACING 19 INCH RIM ldic o P 2 23 2 6 WHEEL LACING 21 INCH RIM Curr m 2 27 PO ANS dei cri a uds EUER EEEN PRX RRST capa MERE So RENE 2 27 2 7 TRUING LACED WHEELS VEI ES NN CE TT 2 31 Lateral TUMO ee 2 31 ml TIMI lt a ccc se E EEE A E E E 2 32 2 8 CHECKING CAST WHEEL
18. a section number followed by a page number For example page 3 5 refers to page 5 in section 3 A number of acronyms and abbreviations are used in this document See the E 1 GLOSSARY for a list of acronyms abbreviations and definitions PREPARATION FOR SERVICE WARNING Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a Good preparation is very important for efficient service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and will reduce the incidence of misplaced tools and parts A motorcycle that is excessively dirty should be cleaned before work starts Cleaning will occasionally uncover sources of trouble Tools instruments and any parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a distraction and causes needless delay NOTES To avoid unnecessary disassembly carefully read all rel ative service information before repair work is started In figure legends the number which follows the name of a part indicates the quantity necessary for one complete assembly When servicing a vehicle equipped with the Harley Dav idson Smart Security System H DSSS you must first disarm the security system Either
19. adjuster screw 1 4 turn Free play at hand lever 1 16 1 8 in 1 6 3 2 mm Clutch inspection cover screw torque 84 108 in Ibs 9 5 12 2 Nm Tire condition and pressure Pressure for solo rider Front 30 psi 207 kPa Rear 36 psi 248 kPa Pressure for rider and passenger Front 30 psi 207 kPa Rear 40 psi 276 kPa Wear Replace tire if 1 32 in 0 8 mm or less of tread pattern remains Wheel spokes Spoke nipple torque 55 in Ibs 6 2 Nm Steering bead bearings Lubricant for neck fitting SPECIAL PURPOSE GREASE Brake fluid reservoir level Brake fluid type D O T 4 brake fluid Proper fluid level front brake 1 4 in 6 35 mm from the top of the reservoir Proper fluid level rear brake Upper fluid level in reservoir Front master cylinder reservoir cover screw torque 9 17 in Ibs 1 0 2 0 Nm Brake pad linings and discs Minimum brake pad thickness 0 04 in 1 02 mm Minimum brake disc thickness See stamp on side of disc 1 8 2008 Sportster Service Maintenance Table 1 4 Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Drive belt Upward measurement force applied at 10 Ib 4 5 kg midpoint of bottom belt strand Belt deflection with motorcycle on jiffy XL 883C XL 883L XL 1200C XL 1200L XL stand belt and sprockets at ambient tem 1200N 1 4 5 16 in 6 35 7 94 mm perature cold
20. all power tools use only recommended accessories with proper capacity ratings Do not exceed air pressure ratings of any power tools Bits should be placed against work surface before air hammers are operated e Disconnect the air supply line to an air hammer before attaching a bit Never point an air tool at yourself or another person Protect bystanders with approved eye protection Wrenches Never use an extension on a wrench handle f possible always pull on a wrench handle and adjust your stance to prevent a fall if something lets go Never cock a wrench Never use a hammer on any wrench other than a STRIKING FACE wrench Discard any wrench with broken or battered points Never use a pipe wrench to bend raise or lift a pipe Pliers Cutters Pry bars Plastic or vinyl covered pliers handles are not intended to act as insulation Do not use on live electrical circuits e Do not use pliers or cutters for cutting hardened wire unless they were designed for that purpose Always cut at right angles Do not use any pry bar as a chisel punch or hammer 2008 Sportster Service Maintenance 1 3 Hammers e Never strike a hammer against a hardened object such as another hammer Always grasp a hammer handle firmly close to the end Strike the object with the full face of the hammer Never work with a hammer which has a loose head Discard hammer if face is chipped or mushroomed Wea
21. belt X X X X X X 1 Throttle brake and clutch controls Check adjust and lubricate X X X X X X 1 Jiffy stand Inspect and lubricate X X X 1 Fuel lines and fittings Inspect for leaks X X X X X X 1 Fuel tank filter screen Clean X 1 Brake fluid Check levels and condition X X X X X X 5 Brake pads and discs Inspect for wear X X X X Front brake lever pin Inspect X X X X 1 2 Lubricate X 1 2 Brake caliper pins Inspect X X X X 1 2 Lubricate X 1 2 Brake caliper boots and bushings Inspect x X X X 1 2 Replace X 1 2 Rear master cylinder outer boot Inspect X X X X X 1 2 Brake components Replace brake rubber components X 1 2 in master cylinders and calipers Lubricate master cylinder pistons X 1 2 Spark plugs Inspect X X X X Replace X Electrical equipment and switches Check operation X X X Engine idle speed Check adjustment X X X X X 1 Front fork oil Replace 1 6 Steering head bearings Adjust X X 1 Lubricate X 1 Rear fork bearings Replace every 30 000 MI 48 000 KM 1 Shock absorbers Inspect X X X X X X 1 Critical fasteners Check tightness X X 1 Engine mounts and stabilizer links Inspect X X 1 Battery Check battery and clean connections 3 Exhaust system Inspect for leaks cracks and loose X X X X X X 3 or missing fasteners or heat shields 2008 Sportster Service Maintenance 1 7 Table 1 3 Regular Service Intervals 2008 Sportster Models ITEM SERVICED PROCEDURE 1000 MI
22. engine without rider or XL 883 XL 883R XL 1200R 9 16 5 8 luggage in 14 3 15 9 mm Air cleaner Air filter element screw torque 40 60 in Ibs 4 5 6 8 Nm Air cleaner cover screw torque 36 60 in Ibs 4 1 6 8 Nm Engine idle speed Idle speed 950 1050 RPM Fuel filter Fuel pump module mounting screw torque 40 45 in Ibs 4 5 5 1 Nm Clutch and throttle cables Lubricant SUPER OIL Handlebar clamp screw torque 108 132 in Ibs 12 2 14 9 Nm Handlebar switch housing screw torque 35 45 in Ibs 4 0 5 1 Nm Spark plugs Type 6R12 Gap 0 038 0 043 in 0 96 1 09 mm Torque 12 18 ft lbs 16 3 24 4 Nm Front fork oil Type HYDRAULIC FORK OIL TYPE E Amount See 1 20 FRONT FORK OIL Battery Lubricant ELECTRICAL CONTACT LUBRICANT Negative terminal screw torque 60 70 in Ibs 6 8 7 9 Nm Positive terminal screw torque 70 80 in Ibs 7 9 9 0 Nm Critical fasteners See 1 29 CRITICAL FASTENERS Engine mounts isolators and Stabilizers See 2 23 FRONT ENGINE MOUNT ISOLATOR 2 24 REAR ENGINE MOUNT ISOLATOR 2 22 STABILIZER LINKS 2008 Sportster Service Maintenance 1 9 Table 1 5 Lubricants Greases Sealants ITEM PART NUMBER PACKAGE Anti Seize Lubricant 98960 97 1 oz squeeze tube CCI 20 Brake Grease 42830 05 included in master cylinder squeeze packet rebuild kit D O T
23. fastener apply a small amount of pressure as a test to be sure the ratchet s gear wheel is engaged with the pawl Sockets Never use hand sockets on power or impact wrenches Select the right size socket for the job Never cock any wrench or socket Select only impact sockets for use with air or electric impact wrenches Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Do not open more than one loaded drawer at a time Close each drawer before opening up another Close lids and lock drawers and doors before moving storage units Do not pull on a tool cabinet push it in front of you Set the brakes on the locking casters after the cabinet has been rolled to your workspace FUEL AND OIL 1 2 FUEL Refer to Table 1 1 Always use a good quality unleaded gas oline Octane ratings are usually found on the pump WARNING Avoid spills Slowly remove filler cap Do not fill above bottom of filler neck insert leaving air space for fuel expansion Secure filler cap after refueling Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00028a WARNING Use care when refueling Pressurized air in fuel tank can force gasoline to escape through filler tube Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00029a
24. keep the fob in close proximity to the vehicle or use Digital Technician to disable the security system while the vehicle is being serviced and re enable the system after service is completed SERVICE BULLETINS In addition to the information presented in this Service Manual Harley Davidson Motor Company will periodically issue Service Bulletins to Harley Davidson dealers Service Bulletins cover interim engineering changes and supplementary information Consult the Service Bulletins to keep your product knowledge current and complete USE GENUINE REPLACEMENT PARTS FOREWORD WARNING Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury 00001a To ensure satisfactory and lasting repairs carefully follow the Service Manual instructions and use only genuine Harley Davidson replacement parts Behind the emblem bearing the words GENUINE HARLEY DAVIDSON stand more than 100 years of design research manufacturing testing and inspecting experience This is your assurance that the parts you are using will fit right operate properly and last longer WARNINGS AND CAUTIONS Statements in this service manual preceded by the following words are of special significance WARNING WARNING indicates a potentially hazardous situation which if not
25. of gas and Harley Davidson recommends you use it when possible as an aid to cleaner air in our environment Donotuse 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 CAUTION 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 Table 1 2 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 Cl 4 The preferred viscosities for the diesel engine oils in des cending order are 20W50 15W40 and 10W40 At the first opportunity see an authorized dealer to change back to 100 percent Harley Davidson oil Table 1 2 Recommended Engine Oils H D TYPE VISCOSITY H D RATING LOWEST AMBIENT COLD WEATHER TEMPERATURE STARTS BELOW 50 F 10 C H D
26. operation Never leave a part suspended in mid air WARNING 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 inspec
27. pas d relier SIE bras EEREE CA AS Pu AdE E I du BUR 1 23 Poi eee eee cee ere rere re ee ere ere re cere eee 1 23 1 10 CLUTCH POSTING HS 1 25 1 11 TRANSMISSION LUBRICANT Transmission Lubrication Sportster Models 1 27 Cheek Lubricant EOuel iunesuacsictone cie moore este 1 27 Changing ICE Sas ined zx pe MUR ERE RD REIR 1 27 1 12 REAR BELT AND SPROCKETS tl e 1 29 uoc 1 29 Hrsg t 1 29 cin rae O ER 1 29 zc icc e m 1 29 1 13 SHOCK ABSORBER ADJUSTMENT Shock Absorber Preload Adjustment Sportster Models 1 31 1 14 REAR BELT DEFLECTION luto eme M 1 32 Belt Deflection Adjustment 1 33 Lil PISIS arii rc 1 34 Checking Wheel Alignment sesssse 1 34 Adjusting Wheel Alignment ssesees 1 35 1 15 BRAKE PADS AND DISCS ISPOCHON M 1 36 cic cr m M 1 36 Brake Disc Thickness Lateral Runout and iuro EN 1 36 Brake Pad Replacement Front sss 1 36 Brake Pad Replacement Rear eessse 1 39 1 16 BATTERY MAINTENANCE c 1 43 Battery Disconnection and Removal 1 44 Cleaning and Inspectigh secco rire rene 1 45 CHAOIN DIG rr 1 45 Barely PrecBUllOls ccce e dr A rU dese 1 45 Using a Batter
28. remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Never use a hammer to drive bushings Inspect the bushing and the mated part for oil holes Be sure all oil holes are properly aligned Gaskets Always discard gaskets after removal Replace with new gas kets Never use the same gasket twice Be sure that gasket holes match up with holes in the mating part But be aware that sections of a gasket may be used to seal passages If a gasket must be made be sure to cut holes that match up with the mating part Serious damage can occur if any flange holes are blocked by the gasket Use material that is the right type and thickness Lip Type Seals Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant Seal orient ation however may vary under different applications Seals should not be removed unless necessary Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement Leaking oil or grease usually means that a seal is damaged Replace leaking seals to prevent overheated bearings Always discard seals after removal Do not use the same seal twice O Ri
29. 1 24 IDLE SPEED AND IGNITION TIMING ale cio A ge SS 1 60 lgnition TMG eann 1 60 1 25 FUEL SUPPLY FILTER CTA A EA AE EEE S E o e aes 1 61 Fuel System Hose and Fittings 1 61 TASA Lotus sex restrain cK Reb FREUT EE GERI 1 61 dS RUN cic Cl PER GRE XOR CRI Ren M ORO eines 1 61 1 26 ENGINE MOUNTS AND STABILIZER LINKS RSG o uE eE E E E 1 62 1 27 HEADLAMP ALIGNMENT Headlamp Alignment Sportster Models 1 63 lp lere e Hm 1 63 Adjustment XL 883C and XL 1200C Models 1 63 Adjustment All Models Except XL 883C and XL 128 DO Oberst ERES UNA Coa Era ELO n RR ERR AERE RD AE T 1 63 IV TABLE OF CONTENTS 1 28 FLUID AND LUBRICANT REQUIREMENTS Brake a ow T 1 65 Brake Component Grease uiuit tata ide aaa 1 65 Fronit FOK Oll Mer enea 1 65 Enone EOM uc aet tenido ntc ER 1 65 Primary Drive Transmission Lubricant 1 65 1 29 CRITICAL FASTENERS rcge ee Xt 1 66 1 30 STORAGE tae eral ios cre cp RED ERU HIPS ADU CUI FU TE ERO VES 1 67 Piacno i SHOE GS Laici oie tiir ehr bei mis Urin t ide cbe odis 1 67 Removal From SDOFae us ssec canendi nada EERRE FRA iK clita 1 67 1 31 TROUBLESHOOTING Ee Lacan dba ERE DUM EAURCE E E A se PEU AREE EROR EA 1 69 DIT 1 69 Starter Motor Does Not Operate or Does Not Turn Engine ssl e 1 69 Engine Turns Over But Does Not Start 1 69 POS Lo PR
30. 1 4 Ratchets and Handles rmt 1 4 cH cj EE 1 4 cic Mc 1 4 1 2 FUEL AND OIL i m RP 1 5 Gasgline IAS M Y 1 5 Engine LIC AN Pt 1 5 SbDlor LOBO io pct e rate dece IRI bedbc pi cd iet iE IM nC S 1 6 1 3 MAINTENANCE SCHEDULE C pr 1 7 1 4 BULB REQUIREMENTS BUD Chali lem C 1 11 1 5 ENGINE OIL AND FILTER Gheckinig and Adding Ilis sis ntn RE Axe t 1 12 Removing and Replacing Oil Filler Cap 1 12 Checking Oil with Cold Engine 1 12 Checking Oil with Warm Engine 1 12 hah Ol SO FOE iua iis aigna Fei Eo crt PARERE Ra t 1 13 prz ec 1 13 Dianin Ol Tabs sei cps ten classe ERES Resa rd pr p US EM Erin 1 13 cuis Be Hl T 1 13 Installing New Qil Fier s pinencs 1 14 Refilling Nri o 1 14 1 6 BRAKES cog c 1 15 r mug were T E 1 15 TEGUDISSITOROUIN oisi ica Ex bod EAD Pie Herde d dus 1 15 1 7 BLEEDING HYDRAULIC BRAKE SYSTEM ovals T E dextri aa cebat Dol beoe T 1 17 c smi sccscecscincsesascecsiatsentecctecensectsecreiantaeite 1 17 Blesding Hear Brake uei me baci tam abei eain id osx d 1 19 1 8 TIRES AND WHEELS i e e 1 20 Tire Replacement rris trrk e fet e texit Rae eeic 1 21 UE 81 eic MEM 1 21 When To Replace Tires inrer een 1 21 big Mr gno er 1 21 idu cielos Pet TT 1 21 1 9 PRIMARY CHAIN HU DEG UOI Ioui
31. 4 Brake Fluid 99953 99A 12 oz bottle Electrical Contact Lubricant 99861 02 1 oz squeeze tube Genuine Harley Davidson Formula 99851 05 1 qt bottle Transmission and Primary Chaincase Lubricant G40M Brake Grease 42820 04 squeeze packet Gray High Performance Sealant 99650 02 1 9 oz squeeze tube HYLOMAR Gasket and Thread Sealant 99653 85 3 5 oz tube Loctite Pipe Sealant With Teflon 565 99818 97 6 ml squeeze tube Loctite Prism Primer 770 Loctite Prism Superbonder 411 Loctite Superbonder 420 Adhesive Loctite Threadlocker 243 blue 99642 97 6 ml squeeze tube Loctite Threadlocker 262 red 94759 99 6 ml squeeze tube Loctite Threadlocker 272 98618 03 10 ml bottle Special Purpose Grease 99857 97 14 oz cartridge Super Oil 94968 85TV 1 4 fl oz Type E Hydraulic Fork Oil 99884 80 16 oz bottle 1 10 2008 Sportster Service Maintenance BULB REQUIREMENTS 1 4 BULB CHART Table 1 6 Bulb Chart 2008 Sportster Models LAMP DESCRIPTION BULBS CURRENT HARLEY DAVIDSON ALL LAMPS 12 VOLT REQUIRED DRAW PART NUMBER AMPERAGE Headlamp high beam low beam 1 4 58 5 0 68329 03 position lamp international 1 0 32 53438 92 Tail and stop lamps tail lamp 1 0 59 68167 04 stop lamp 1 2 10 68167 04 tail lamp international 1 0 59 68167 04 stop lamp international 1 2 10 68167 04 Turn signal lamp front running 2 2 25 0 59 68168 89A front international 2 1 75 68163 84 rear 2 2 25 68572 64B rear international 2 1
32. 5 8 BIcinI Tp e M 5 8 co jo fe 5 8 voleno SZORLSCIS i riens e pe RS a EUH Ea EHE AR pip saanenisuipesaeaaniate 5 8 Disassaembby u uiu ice ces to rtriri E 5 8 PASSO DB oder ead De EFE Spr AL dbeleos desea ek PR TU 5 9 DRIVE TRANSMISSION 6 1 SPECIFICATIONS DRIVE 2008 Sportster SpecilicallOrs snos eaa reper etae Rae beni nhas 6 1 6 2 PRIMARY CHAIN ADJUSTER ETUDES OI OE 6 2 Remova 6 2 Piman WER Lat esistere eM EibF Gab MU Sa E M MMENO 6 2 Primary Chain Adjuster seseesessss 6 4 utate Mm M 6 4 Primary Chain AJUSTEN accensi inicr 6 4 Pamay Eos T 6 5 6 3 CLUTCH RELEASE MECHANISM Removal and Disasserbly cere rms 6 7 TABLE OF CONTENTS IX TABLE OF CONTENTS Cleaning Inspection and Repair esse 6 8 Assembly ANG Ingtellallriue iscritti tne Ernte 6 8 6 4 PRIMARY DRIVE AND CLUTCH ij Meme 6 10 gie e 6 12 PSAs Se ONY Meet T I 6 12 Inspection and Papalf erret ed tt erre 6 13 FSS UG Mee 6 14 NRA NO t 6 15 6 5 SECONDARY DRIVE BELT EN E E 6 17 Mara Geo 6 18 6 6 TRANSMISSION Cene dlei a E G 6 20 6 7 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL Cene daina RG 6 21 Engine Removal and Disassembly 6 21 6 8 TRANSMISSION REMOVAL AND DISASSEMBLY Transmission Removal From Left Crank
33. 5000 MI 10 000 MI 15 000 MI 20 000 MI 25 000 MI NOTES 1600 KM 8000 KM 16 000 KM 24 000 KM 32 000 KM 40 000 KM Road test Verify component and system func X X X X X tions NOTES 1 Should be performed by an authorized Harley Davidson dealer unless you have the proper tools service data and are mechanically qualified 2 Replace every four 4 years 3 Perform annually 4 Not all vehicles are equipped with spoke wheels Consult appropriate topic in service manual 5 Replace every two 2 years 6 Disassemble lubricate and inspect every 50 000 miles 80 000 km Table 1 4 Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Engine oil and filter Oil capacity 2 8 qt 2 65 L Filter Hand tighten 1 2 3 4 turn after gasket contact Chrome filter XL 1200C Part no 63796 77A Black filter all except XL 1200C Part no 63805 80A Primary chain tension Deflection with hot engine 1 4 3 8 in 6 3 9 5 mm Deflection with cold engine 3 8 1 2 in 9 5 12 7 mm Chain tensioner nut torque 20 25 ft lbs 27 1 33 9 Nm Primary chain inspection cover screw torque 40 60 in Ibs 4 5 6 8 Nm Primary chain transmission lubricant Lubricant capacity 32 oz 946 mL Primary chaincase drain plug torque 14 30 ft lbs 19 0 40 7 Nm Lubricant Genuine Harley Davidson Formula Transmission and Primary Chaincase Lubricant Clutch adjustment Free play at
34. 75 68163 84 Instrument panel Illuminated with LEDs Replace entire assembly upon failure Functions as turn signals tail lamps and brake lamps on 1200N model 2008 Sportster Service Maintenance 1 11 ENGINE OIL AND FILTER 1 5 CHECKING AND ADDING OIL Check engine oil level in oil tank and add oil if necessary Oil tank capacity wet is 2 8 quarts 2 65 liters Refer to Table 1 2 for recommended engine oil viscosity CAUTION Oil level cannot be accurately measured on a cold engine For pre ride inspection with motorcycle leaning on jiffy stand on level ground oil should register on dipstick between arrows when engine is cold Do not add oil to bring the level to the FULL mark on a COLD engine 00185a Removing and Replacing Oil Filler Cap 1 See Figure 1 1 Position motorcycle so that it is leaning on jiffy stand on level ground Remove filler cap from oil tank on right side of vehicle a Press straight down on filler cap and release Cap will pop up b Pull up on filler cap while turning counterclockwise one quarter turn as if unscrewing filler cap 2 Wipe attached dipstick clean NOTE See Figure 1 2 Note that dipstick has a wide slot 1 and a narrow slot 2 and can only be inserted in oil tank one way 3 Insert dipstick into tank Turn filler cap clockwise one quarter turn as if screwing filler cap into tank When filler cap stops turning it is fully sea
35. EE RES an 7 68 STAN AUCs ERIT ET T T 7 69 7 30 JIFFY STAND SWITCH INTERNATIONAL MODELS General c 7 71 is e Mec ae een Zh rius m 7 72 7 31 OPTIONAL SECURITY SIREN glo e 7 78 inel T I 7 73 nico Qi pete NE 7 73 Battery Replace Mireia 7 74 E 5 lS A E Anan O E ee 7 74 WS aU SOOM a E E E E E E E E E ito 7 32 OIL PRESSURE SWITCH tig cass 7 76 ROOY lls Meer 7 76 rius EN 7 76 7 33 HORN ice hls oi oie 9 1 ys Re eer eae dere rere eer EA iG ecd a UE been Na 7 77 volage WS eras ctanadcaesatcesiasarausncmnedeansitansitiecteacconeete natant 7 77 Replacement Models with Front Mounted Horn 7 77 Replacement Models with Side Mounted Horn 7 77 7 34 MAXI FUSE Cene 7 79 gpl e EM Z 79 irri e 7 79 7 35 HANDLEBAR SWITCH ASSEMBLIES Cener M 7 80 Repair Procedur d 7 80 COMING ONS E T EEN A E S E UA AE 7 81 7 36 RIGHT HANDLEBAR SWITCHES REMOVA oense iA ET HA 7 82 Dasso mbl e 7 82 Switch Repair Replacement sees 7 83 Upper Housing Repair rrr 7 83 Lower Housing Repairs 7 83 Tura Right Signal Swiieh serseri 7 84 XII TABLE OF CONTENTS Front Stoplight SWN 7 84 E p A E E AE AE E T 7 84 Macareo meter E E E E 7 85 7 37 LEFT HANDLEBAR SWITCHES
36. HARLEY DAVIDSON 2008 Sportster Models Service Manual ALL RIGHTS RESERVED 99484 08 VISIT THE HARLEY DAVIDSON WEB SITE ABOUT THIS MANUAL GENERAL This Service Manual has been prepared with two purposes in mind First it will acquaint the user with the construction of the Harley Davidson product and assist in the performance of basic maintenance and repair Secondly it will introduce to the pro fessional Harley Davidson Technician the latest field tested and factory approved major repair methods We sincerely believe that this Service Manual will make your association with Harley Davidson products more pleasant and profitable HOW TO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual z o CHAPTER Maintenance Chassis Engine Fuel System Starter Drive Transmission Electrical Appendix A Connector Repair Appendix B Wiring Appendix C Conversions Appendix D Compensating Sprocket m olol pPI ola A wl rp a Appendix E Glossary Use the TABLE OF CONTENTS which follows this FORE WORD and the INDEX at the back of this manual to quickly locate subjects Sections and topics in this manual are sequentially numbered for easy navigation For example a cross reference shown as 2 1 SPECIFICA TIONS refers to chapter 2 CHASSIS heading 2 1 SPECIFIC ATIONS For quick and easy reference all pages contain
37. I EE T ery 4 43 LNG TEST T ssibdadad 4 43 xc mk TTE 4 43 l 4 ue 4 43 Tester AocpustI mont iria Pra is br alae rR Pr bnaE 4 43 POCO UIC eem 4 43 4 16 EVAPORATIVE EMISSIONS CONTROL CA MODELS Ir qr MR ER 4 45 TABLE OF CONTENTS ua CIEL 4 45 gir P P 4 45 jii css tes E 4 46 yapar UAE E 4 47 ui e 4 47 piri cup RM P M 4 47 Hose uieib Qo 4 48 Maucor Module so picos erbe ilr fe eid oben IDA DE 4 48 Canister Hose Roulings rrrerr rne 4 48 STARTER 5 1 SPECIFICATIONS STARTER Specifications 2008 Sportster Models 5 1 5 2 STARTER BONE al 5 2 olg c sich mU TE 5 2 Wining DIspralis uus oco eucuc ris cx eivai nier even vene x tn 5 2 PS Ue Mem CT 5 2 iac SPEO EE OD 5 2 TO BI accuse acea sq bi see ou bie meen EE Eb ca edo ulis fe uai d edid 5 2 toy Ee tS eU E 5 2 Brushes and Brush Holder sisisiisroriiresiaascinarsia 5 5 Figli Goil ASSEN uus indi rial rc ER ERRARE XE ELO LAT ERU EE 5 6 BI LLI ue 5 6 lier sue eee E R 5 6 PS SOU onen EE 5 6 Driye Assembly eoria O E 5 7 Disassembly snoin 5 7 Hepe ioia E 5 7 AS Se aa ERS 5 7 5 3 STARTER SOLENOID Solenold Assembly uie aci sa t bri Maa Ri e e 5 8 DBAS SOMONE d mp 5 8 BOSQUE repas ts couse nae uxei dee MEE xa LES UTOR AERA GEO Gd 5 8 Solenoid PINE uec ror EE RIMIS PH ean
38. Install end of a length of 5 16 in 7 9 mm I D clear plastic tubing over caliper bleeder valve Place free end of tube in a clean container 6 Squeeze and hold brake lever to build up hydraulic pres sure See Figure 1 12 Open bleeder valve 2 about 1 2 turn Brake fluid will flow from bleeder valve through tubing Observe fluid flowing through tubing Check for air bubbles 7 Close bleeder valve when brake lever has moved 1 2 to 3 4 of its full range of travel Allow brake lever to return slowly to its released position 8 Repeattwo previous steps until all air bubbles are purged from system 9 Final tighten bleeder valve to 35 61 in Ibs 4 0 6 9 Nm Remove plastic tubing and install bleeder cap 3 10 See Figure 1 11 Add enough HARLEY DAVIDSON D O T 4 BRAKE FLUID to reservoir to bring fluid level even with ridge cast into inside of reservoir about 1 4 in 6 35 mm below top edge 1 18 2008 Sportster Service Maintenance 1 Front brake caliper 2 Bleeder valve 3 Bleeder cap Figure 1 12 Front Brake Caliper sm01424 Figure 1 13 Bleeding Hydraulic System 11 If bleeding vehicle equipped with dual front disc brake system repeat this procedure for other caliper 12 See Figure 1 10 Replace diaphragm 2 diaphragm plate 3 and reservoir cover 4 with captive screws 5 Tighten to 9 17 in Ibs 1 0 2 0 Nm WARNING After repairing the brake system test brakes
39. It is not necessary to drain engine crankcase 5 Replace drain plug into end of drain hose and tighten worm drive clamp securely Cil tank drain hose Worm drive clamp Drain plug No Figure 1 5 Oil Tank Drain Hose Removing Oil Filter 1 Place a drain pan beneath front of engine crankcase CAUTION Use Harley Davidson OIL FILTER WRENCH for filter removal This tool can prevent damage to crankshaft position sensor and or sensor cable 00192a 2 See Figure 1 4 See Figure 1 6 Remove oil filter using HARLEY DAVIDSON OIL FILTER WRENCH Part No HD 42311 or HD 44067 A Turn oil filter counterclock wise to remove from filter mount 3 Drain oil filter into drain pan Discard oil filter Clean any oil spills off crankcase and frame 2008 Sportster Service Maintenance 1 13 me 1 Oilfilter mount 2 Oil filter Figure 1 6 Oil Filter All Models XL 1200C Shown Installing New Oil Filter NOTE Partially fill oil filter before installation to minimize the time required for buildup of oil pressure when engine is first started 1 Pour about 4 fluid ounces 120 ml of fresh clean engine oil into new oil filter Allow time for oil to soak into filter element 2 Wipe filter gasket contact surface of oil filter mount with a clean cloth 3 See Figure 1 7 Coat oil filter gasket with clean Harley Davidson 20W 50 engine oil NOTE Do not use oil filter wrench to install new oil f
40. LSDEE E M UBER EUPELE ee eons 7 12 lite te coca iitoe ka danse Acc M ga PRI ERA rh eR ab epa hdi dcr CU Ob Fees 7 13 7 8 TURN SIGNAL AND SECURITY MODULE TSM TSSM HFSM EL EE COST D Su Dm 7 14 E oc re E 7 14 Removal annata ian 7 14 ASN ANON ove cio a Pe Eee EG EE OE AAT 7 15 7 9 BATTERY CABLES REMOVA eraa 7 16 etalat a A 7 17 7 10 BATTERY TRAY 7 11 IGNITION SYSTEM TCT arene eo E E oe eee uou A UD creer 7 20 Herten g0ome 7 20 7 12 IGNITION AND LIGHT SWITCH POET ies cord to Seu eines quU Etico a 7 22 REMOVA gga e PPP 7 22 Iris ERU c iier ts casa Rape toS rREPII POR to Pes EIE C UHR IS S REPRE 7 22 7 13 ELECTRONIC CONTROL MODULE ECM VETT IUS MR EI TOT T E TOTO 7 24 FRITS Vall e S 7 24 RETE PDT E E E S Som 7 24 7 14 SPARK PLUG CABLES SITE sects cows spei tres et beth epa EE SEHR E 7 25 giae M 7 25 IgE lira TTC 7 26 7 15 IGNITION COIL CORTE ico roan ba edidu tub a icu o cR a iR dion 7 27 Troubleshooting siiin 7 27 zip eT 7 27 ra RON cei eie bra MEER XS E PA RERUM I DxE ML CRM A 7 28 7 16 CHARGING SYSTEM i r BRE p RE tees 7 29 rdi gr rp 7 29 volage FlegulBlDE issn E 7 29 7 17 HEADLAMP Replacement XL 883C XL 12000 ns 7 30 Replacement All Models Except XL 883C XL 1200C 7 32 7 18 INDICATOR LAMP MODULE VE TI Id REN RR TE 7 34 Preliminary Disassembly All Models 7 34 Replacement
41. Multi grade SAE 10W40 HD 360 Below 40 F 4 C Excellent H D Multi grade SAE 20W50 HD 360 Above 40 F 4 C Good H D Regular Heavy SAE 50 HD 360 Above 60 F 16 C Poor H D Extra Heavy SAE 60 HD 360 Above 80 F 27 C Poor 2008 Sportster Service Maintenance 1 5 WINTER LUBRICATION 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 to 1500 miles 2400 kilometers Motorcycles used only for short runs must have a thorough tank flush out before new oil is put in The tank flush out should be performed by an authorized dealer or qualified technician NOTE The further below freezing the temperature drops the shorter the oil change interval should be 1 6 2008 Sportster Service Maintenance Water vapor is a normal by product of combustion in any engine During cold weather operation some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine In freezing weather this water will become slush or ice and if allowed to accumulate too long may block the oil lines and cause damage to the engine If the engine is run frequently and allowed to thoroughly warm up most of this water will become vapor again and will be blown out through the crankcase breather If the engine is not run frequently and allowed t
42. ORK STEM AND BRACKET ASSEMBLY Removal and Disassembly sess 2 83 Cleaning Inspection and Repair sssssse 2 83 Assembly and Installation eeeeseeeeeess 2 84 2 19 BELT GUARD AND DEBRIS DEFLECTOR SI NEU n 2 85 ai i e E 2 85 teU o a e T 2 85 Debits Dele f X 2 85 ROMOYA MTTP 2 85 yr rw m 2 85 2 20 REAR FORK xig e 2 86 MICI ip e 2 86 Cleaning and Inspectioh uiuere rrr ttr errem 2 87 Dj e 2 87 Jar s e 2 87 2 21 SHOCK ABSORBERS CEU aset iA MT E A TEE 2 89 Removal aeae 2 89 Cleaning and IMSpectON srsirsaaiiirisusiiirsiiiisinassussnani 2 89 MNG aara 2 89 2 22 STABILIZER LINKS tg arinrin e eae 2 90 Upper Front Stabilizer Link eseeeeeseesss 2 90 csl 2 90 riri sos ccc achat 2 90 Lower Front Stabilizer Link eeeceesceeeeeeeseeeeeeeeneetees 2 90 RII Ted 2 90 Dei E a MET Tm 2 90 3 lik is pi MH MERC c 2 91 i piper NM qd UE 2 01 liri ri Po 2 91 2 23 FRONT ENGINE MOUNT ISOLATOR Removal e 2 92 uiis eee n 2 93 2 24 REAR ENGINE MOUNT ISOLATOR g ur raen 2 94 RSID scat cd Sac T 2 95 2 25 THROTTLE CABLES Removal and Disassembly esee 2 97 Cleaning
43. P A 2 111 PREVI El dass scss cats eu ga a e NM EM ONERE Eric tn abis 2 111 lastalla hio socia ro vieta S 2 113 2 30 REAR FENDER AND LICENSE PLATE BRACKET XL 1200N ae pec orb vaio tm ERU ERE ICH E 2 115 Removal and Dissssembly uscite ct ck eec ies 2 115 Assembly ano InStellatiGn ui iussaceuciuscis ena ia diitinit nici 2 117 2 31 JIFFY STAND EUN SUCI ETE EO EN 2 120 Jiffy Stand Interlock International Models 2 120 PEIUS NIMES NONEM d ed 2 120 Cleaning and BUbrIcalldim uisi oir erra apris rero ree 2 120 Crete S ey See E E ae oe toe E bai tie qs 2 121 2 32 SEAT MEW i EE RERBA RERUM EU 2 122 GS PBRCBRONGILL a ee uie iren d EE aet Eee dine 2 122 Seat SUA Rr 2 122 2 33 RIDER FOOT CONTROLS ALL MODELS EQUIPPED WITH MID MOUNT CONTROLS Right Footrest and Rear Brake Pedal Assembly 2 124 ERGO coena bacon PE Y p BRE terii E c Eo ei as 2 124 SCENT eee EE THE 2 124 Left Footrest and Shift Lever Assembly 2 124 PPO UA oos see siMipene Rd ese ae 2 124 lristelle Ses ori shou dace ERR Edd e dese rabies MER odds 2 124 2 34 RIDER FOOT CONTROLS ALL MODELS EQUIPPED WITH FORWARD CONTROLS Right Footrest and Rear Brake Pedal Assembly 2 126 PRE EGA REPRE 2 126 Rate Mem E E E 2 126 Left Footrest and Shift Lever Assembly 2 127 Rice 2 127 Iul PNE TTE 2 128 Adusting Shit Pel iriser 2 129 2 35 PASSENGER FOOTRESTS cog c iee 2 130 PINE
44. RUNOUT ETE oe eco Se er ee mere er or eee ee renee 2 34 Lateral BUBOUE iia sccesiscassncsatiaenietaiomarananreasanvaaxes Rx Ure seas 2 34 asp mee CP T 2 34 2 9 FRONT BRAKE MASTER CYLINDER a C 2 35 HAS FSG ji NUT p 2 35 FRITS Vall e 2 35 BEIC POET TET OT OE 2 36 Cleaning Inspection and Repair sesssse 2 39 noc np esee TEE 2 39 REUS DONOR R 2 40 2 10 FRONT BRAKE CALIPER ai upeu MP UTR 2 43 RII I por Mt 2 44 Cleaning Inspection and Repair esses 2 46 PAS SO Bi fet 2 47 Lubricating Front Caliper Bolt Pins and Boots 2 47 TABLE OF CONTENTS Installing Brake Pads in Caliper 2 48 Hi ANON losses vers nance E be E E D e ru AES Aa MARRE Md REA 2 49 2 11 REAR BRAKE MASTER CYLINDER Se ROS sd spei ere Ur rie USER PEN ee en reer haere ra ER ERU ree 2 51 lure e 2 51 xal e 2 51 DISASS SING e 2 54 Cleaning Inspection and Repair ssesss 2 55 Dri y REM p UNES 2 56 Weis eal NAN icesecsi fe E 2 58 2 12 REAR BRAKE MASTER CYLINDER RESERVOIR cri E 2 50 PUP ls T ieaainen 2 50 licuit e 2 60 2 13 REAR BRAKE CALIPER Removal p 2 61 PS AS SONNY ee 2 63 Cleaning Inspection and Repair
45. SCH STANDARD TERMINAL REPAIR Deutsch Standard Terminal Crimps A 16 Preparing Wire Leads for Crimping A 16 Crimping Terminal to Lead sse A 16 DSS SOIC Dips uucaeetietapcaris aie tesa b esuatad acris Peta A 16 A 8 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR Deutsch Solid Barrel Terminal Crimps A 17 Preparing Wire Leads For Crimping A 17 Adjusting Crimper TOOL nitor tre rores A 17 Crimping a Barrel Contact To Wire Lead A 17 TSEC CHIN DSi A 17 A 9 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal Crimps esesseses A 19 Preparing Wire Leads for Crimping A 19 Crimping a Mini Terminal to Wire Lead A 19 Heri iuge nn A 19 A 10 MOLEX CONNECTORS Molex Connector Repair seeeeeeeeeese A 20 Separating Pin and Socket Housings A 20 Mating Pin and Socket Housings A 20 Removing Terminals suiriri A 20 installing Terminal Snine A 20 Grm Terminal Io Lead e tbe Ese i Est bert er enn A 21 Prepare l Ba em iia a A 21 Prepare Tero eet A 21 Position Terminal in the Punch Die A 22 lnser Stripped Legga usua iiiter desees A 22 Crimp Terminal to Lead en ritirare A 22 Ieri CNP me
46. SO A 2 130 ze 2 130 lr 2 130 2 36 FORK LOCK i araea 2 131 Lg 11 1 ura RT S 2 121 ENGINE 3 1 SPECIFICATIONS Specifications 2008 Sportster Models 3 1 3 2 ENGINE c MEIE METRI E E ETE CEPS 3 6 3 3 OIL PRESSURE FUG E PA E A E ETEN E E A AANT 3 7 Oil Pressure Indicator Lamp nocere 3 7 Checking Oll PEeSSUES uertice Eo cesssinederensesisectaa scons 3 7 3 4 CRANKCASE BREATHING SYSTEM EEE re Renee Ferre EET 3 10 3 5 TROUBLESHOOTING Diagnosing Valve Irain N IB6 cistesisccucectsceitececanatecadsacosice 3 11 G m r ssla TOSE aiaia s Les US rana EXHI Hi MAT RERR e DS 3 11 Cylinder Leakage Testusuuccuniec ses eniciice tienda capies 3 11 Diagnosing Smoking Engine or High Oil Consumption 3 12 Check Prior to Cylinder Head Removal 3 12 Check After Cylinder Head Remowval 3 12 Adjustment and Teslirigu uice ro tree Eee tans 3 12 Generatia 3 12 3 6 ENGINE LUBRICATION SYSTEM Ig mer 3 13 C RUN na T 3 13 3 7 HOW TO USE THIS SECTION E EEEE E A E E AA A O E TEN 3 18 WP ENG RODI m EN 218 Bottom End FROpal seed D aia 3 18 3 8 TOP END SERVICE Engine am GSS S s sese ea edidisse dE bra EP Ee le EE 3 19 Engine Removed from Chassis esssss 3 20 TABLE OF CONTENTS 3 9 BOTTOM END SERVICE Engine ii Chas Me 3 21 Engine Removed From Chassis
47. Specifications 2008 Sportster Models 4 1 4 2 ELECTRONIC FUEL INJECTION EFI Tbe OGGI snua 4 2 4 3 AIR CLEANER EIS ID Meer eum nn rr trent Teri nE 4 3 Cleaning Inspection and Repair esse 4 3 sati soror bet T aA 4 4 4 4 FUEL TANK cree ECC 4 5 Purging and Disconnecting Fuel Supply Hose 4 6 Removing Fuel Tees scacecere eost otia cuiu ban sapo tae ia cap scdiup cicd 4 6 Cleaning and Inspection eeeseeseeseeeeene 4 7 Hac Mm Nm T 4 7 Reconnecting Fuel Hose and Filling Fuel Tank 4 8 Vapor ci Enakan E 4 8 Console Replacement weiiatstearcssirsirapnemateraunmaitiniind 4 9 ali 4 9 JL c co t CH 4 10 4 5 THROTTLE POSITION SENSOR TPS crit aaa 4 12 2p 7 C eee 4 12 MNS TAN AMIN em 4 12 4 6 ENGINE TEMPERATURE SENSOR ET i r E E E 4 14 Ie E E E camry E E E E EE 4 14 tC jeg mem 4 15 4 7 INDUCTION MODULE c r e 4 16 XII Moe 4 16 DISASS OND 4 18 PSS ge mem sess snes A E 4 19 msalala Msa 4 20 4 8 IDLE AIR CONTROL IAC Eal ERE T TM 4 22 aie M AE 4 22 geli p 4 23 4 9 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR TMAP THOME e E E iin ci nie ei Ex Ris beud Eis ga IV s cya RR 4 24 ize vcl EE 4 24 Iria GIRL ooi iere cue opo notorie Pd ru pe EIE CEP AER SER PEE 4 24 4 10 OXYGEN SENSOR Cerera ios ced
48. TOFUSE ELECTRICAL CONNECTORS Autofuse Connector Repair eeseeeeese A 7 jl e mem A 7 DBAS SSRI e A 7 rcg f A 7 A 4 DELPHI CONNECTORS Delphi Connector Ppalr ecc einer rRe annee A 8 Iq m A 8 Separating Pin and Socket Housings A 8 Mating Pin and Socket Housings A 8 Removing Socket Terminals A 8 Installing Socket Terminals A 8 A 5 DELPHI MAXI FUSE HOUSING Delphi Maxi Fuse Housing Repair A 10 crar Mec E A 10 Removing Max FUSE ciroen ea A 10 installing Max FUSE iniainiieinnaa A 10 Removing Socket Terminals A 10 Installing Socket Terminals oai caes A 10 A 6 DEUTSCH ELECTRICAL CONNECTORS Deutsch Connector RED Alii ccsicicccrascciacusscoristomtusscesnaeeia A 12 MAGS TOt eco EG METEO sama PEEL TANE MAIER A 12 Separating Pin and Socket Housings A 12 Mating Pin and Socket Housings A 12 Removing Socket Terminals A 12 Installing Socket Terminals A 12 Removing Pini Terminals rers A 14 installing Pin Terminals uiuis eio reso R ore eR teras A 14 CHIMING Terminal S eee ette reri prEPe ESI a oreja A 15 A 7 DEUT
49. aft Bearings 9 52 Installing Left Main Bearing 3 54 Assembling Crankcase Halves 3 54 Installing Cylinder Base Studs 3 57 Cam Gears and Gearcase Cover 3 57 jio 3 60 Assembling Top End of Engine 3 61 3 16 VALVE TAPPETS cr m 9 3 62 BRAN eR p 3 62 Cleaning and ISHS COM seurina 3 62 M OU UID iiss ates E E Ho etii ahve e tbi a eae es 3 62 3 17 GEARCASE COVER AND CAM GEARS c r Mc PE 3 63 Removal and Disassembly esee 3 63 Cleaning Inspection and Repair ssssss 3 63 TABLE OF CONTENTS VII TABLE OF CONTENTS Cam Pinion Gear Identification Inspection and op ei e A PEENE NEE AT A ARR NER E ERR 3 63 Bushing Inspection and Removal 3 64 Bushing MstallatiOni s ico terii spreto pet reor tei enn rdc S Rd 3 65 Cam Gear Bushings in Right Crankcase 3 65 Cam Gear Bushings Except Rear Intake Bushing in Gedrcase COVEN ES 3 65 Rear Intake Cam Gear Bushing in Gearcase Cover 3 65 Pinion Shaft Bushing in Gearcase Cover 3 65 crura E 3 66 Cam Gear Bushings in Right Crankcase 3 66 Cam Gear Bushings Except Rear Intake Bushing in ECC COUN e 3 67 Rear Intake Cam Gear Bushing in Gearcase Cover 3 67 Pinion Shaft Bushing in G
50. at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 13 Test ride motorcycle at low speed Repeat the above bleeding procedure if front brake feels spongy BLEEDING REAR BRAKE CAUTION D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 10 NOTES If D O T 4 brake fluid contacts painted surfaces IMMEDI ATELY flush area with clear water See Figure 1 14 Vehicle must be upright so that rear brake master cylinder reservoir 1 is in a level position when filling and checking fluid level Reservoir cover 5 may be removed from rear brake master cylinder reservoir to more easily verify fluid level in reservoir Use only HARLEY DAVIDSON D O T 4 BRAKE FLUID from a sealed container Do not overfill reservoir Do not reuse old brake fluid Position motorcycle upright not resting on jiffy stand See Figure 1 14 Unscrew and remove reservoir cap 2 If desired remove reservoir cover 5 by grasping cover and gently pull straight out from reservoir 1 Add HARLEY DAVIDSON D O T 4 BRAKE FLUID to master cylinder reservoir 1 until the fluid reaches the upper fluid level 3 See Figure 1 15 Remove bleeder cap 3 Install end o
51. avoided could result in death or serious injury 00119a CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 00139a CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage 00140a NOTE Refers to important information and is placed in italic type It is recommended that you take special notice of these items Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this service manual are effective methods for performing service operations WARNING Always wear proper eye protection when using hammers arbor or hydraulic presses gear pullers spring com pressors slide hammers and similar tools Flying parts could result in death or serious injury 00496b Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as recommended It is important to note that some warnings against the use of specific service methods which could damage the motorcycle or render it unsafe are stated in this service manual However please remember that these warnings are not all inclusive Inadequate safety precau tions could result in death or serious injury Since Harley Davidson could not possibl
52. case 6 25 Mainshaft Countershaft esse 6 28 Maishat DISasgembly iu aces eit iiie cd seco ede teria doped 6 29 Cleaning and Inspection esssssss 6 30 Countershaft Disassembly sssrinin 6 30 Cleaning and INSPHECHON ccsarsesceseesesscocsarsesceesaceess 6 30 6 9 TRANSMISSION ASSEMBLY Maimshatt ASSEDI cressa 6 32 Countershaft Assembly eere ene 6 32 6 10 MAIN DRIVE GEAR AND BEARING CRT scontro A Aire pen ee Seta LO uec ON d 6 34 d gre I EE E E E E E E T 6 35 Main DIV GERi issiran E 6 35 Main Drive Gear Ball Bearing 6 36 Ds OND RETE 6 36 PS SS TOI e 6 36 lr ee M 6 37 Main Drive Gear Ball Bearing 6 37 Maim Dive Geal noresi ctae Cyri pes ibas 6 38 Main Drive Gear Seal errore tenens 6 40 6 11 TRANSMISSION RIGHT CASE BEARINGS per e M E 6 43 Countershaft Needle Bearing 6 43 Shiner Drum Bushilig oue eiiis iier ters aaa 6 43 ir riri eee 6 43 Countershaft Needle Bearing 6 43 Shifter Der BUSH nss 6 43 X TABLE OF CONTENTS 6 12 TRANSMISSION LEFT CASE BEARINGS REMOVA eem 6 44 Mainshaft and Countershaft Bearings 6 44 Shifter Drum BUS MNG iriiritia 6 44 Tie EA Ne ein AE E E eae 6 44 Mainshaft and Countershaft Bearings
53. earcase Cover 3 67 Assembly and Installation eeeeseeeeeess 3 68 3 18 CYLINDER HEAD Removal e 3 69 DrassemD Mee M a 3 69 Cleaning and ImspecltioR iuseses reor rut tot eres 3 71 Cylinder Poad em 3 71 Rocker Arm Assemblies cene 3 71 WA WINS E E E E E E E E 3 73 EEL E e A E ATE AIE NTE EIN 3 73 VaVe CALA TA 3 73 vake SIS iiaiai isai 3 73 Spark Plug WTC RES o5 scoieecraneavstenperscteiciviesraneinintese 3 74 roc 3 74 Replacing Rocker Arm Bushings esses 3 74 Replacing Valve Guides sse 3 75 Removal e 3 75 riri PT 3 76 Fieraelbg Valve DOSES p AU a ADU cadran 3 79 Replacing Valve Seals ieeicstot cette pes itu Ria 3 80 Fi AOI Lis A Foi IUS ERE REESE parva E E eae 3 80 jr ri ta saccacoct E E E 3 83 3 19 CYLINDER AND PISTON Removal and Disassembly sees 3 84 Cleaning Inspection and Repair sssssss 3 84 Checking Gasket Surface esesssss 3 84 Measuring Cylinder Bore esses 3 84 Measuring Piston to Cylinder Fit 3 85 Boring and Honing Cylinder sassinoro 3 86 Fitting Pistoi RiNS agaa 3 86 Connecting Rod BUSMINGS cccisccisiissscisninesescescvescmeccinaneays 3 88 Removing Upper Connecting Rod Bushing
54. f a length of 5 16 in 7 9 mm I D clear plastic tubing over caliper bleeder valve 2 Place free end of tube in a clean container Depress and hold brake pedal to build up hydraulic pres sure Open bleeder valve about 1 2 turn Brake fluid will flow from bleeder valve through tubing Observe fluid flowing through tubing Check for air bubbles Close bleeder valve when brake pedal has moved 1 2 to 3 4 of its full range of travel Allow brake pedal to return slowly to its released position Repeat two previous steps until all air bubbles are purged Final tighten bleeder valve to 35 61 in Ibs 4 0 6 9 Nm Remove plastic tubing and install bleeder cap See Figure 1 14 Add HARLEY DAVIDSON D O T 4 BRAKE FLUID to master cylinder reservoir 1 until the fluid reaches the upper fluid level 3 Replace reservoir cap 2 Replace reservoir cover 5 if removed WARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 11 Test ride motorcycle at low speed Repeat the above bleeding procedure if rear brake feels spongy NS sm01425 Rear brake master cylinder reservoir Reservoir cap Upper fluid level Lower fluid level Reservoir cover Penn Figure 1 14 Rear Brake Master Cylinder Reservoir 1 Rear brake caliper 2 Bleeder valve 3
55. handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir Spilling brake fluid on handlebar switches may render them inoperative WARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a INSPECTION Check the master cylinder reservoirs for proper fluid levels With the reservoir in a level position add HARLEY DAVIDSON D O T 4 BRAKE FLUID from a sealed container until the fluid level is within approximately 1 4 inch 6 35 mm below the top edge of the reservoir front brake or reaches the upper fluid level in the reservoir rear brake Do not overfill the reservoir See 1 7 BLEEDING HYDRAULIC BRAKE SYSTEM for procedures related to filling reservoirs Check brake pads and discs for wear Replace brake pads if friction material is worn to 0 04 in 1 02 mm or less Minimum brake disc thickness is stamped on side of disc Replace any brake disc that is worn beyond this limit Maximum brake rotor lateral runout and warpage is 0 008 in 0 2 mm when meas ured near the outside diameter For disc replacement procedures see 2 3 WHEELS For brake master cylinder service see 2 9 FRONT BRAKE MASTER CYLINDER or 2 11 REAR BRAKE MASTER CYLINDER For brake caliper service see 2 10 FRONT BRAKE CAL IPER or 2 13 REAR BRAKE CALIPER
56. hat top of front master cylinder reservoir 1 is level 2 See Figure 1 10 Remove reservoir cover 4 with two captive screws 5 diaphragm plate 3 and diaphragm 2 from master cylinder reservoir 1 m sm01420 1 Front brake master cylinder and reservoir 2 Cover screw 2 3 Top cover Figure 1 9 Front Brake Master Cylinder Reservoir sm01421 1 Front brake master cylinder assembly 2 Diaphragm 3 Diaphragm plate 4 Reservoir cover 5 Captive screw 2 Figure 1 10 Front Brake Master Cylinder Cover Assembly NOTES e See Figure 1 11 Do not use sight glass 2 to determine maximum fluid level Sight glass should only be used as a visual indicator that fluid level is low and needs attention 2008 Sportster Service Maintenance 1 17 A ridge 1 is cast into the inside of the reservoir to assist you in determining the correct level Use only HARLEY DAVIDSON D O T 4 BRAKE FLUID from a sealed container Do not overfill reservoir Do not reuse old brake fluid sm01422 1 Cast in ridge 2 Sight glass Figure 1 11 Filling Front Master Cylinder Reservoir 3 SeeFigure 1 11 Add enough HARLEY DAVIDSON D O T 4 BRAKE FLUID to reservoir to bring fluid level even with ridge 1 cast into inside of reservoir about 1 4 in 6 35 mm below top edge 4 See Figure 1 12 Remove bleeder cap 3 from bleeder valve 2 on front caliper 1 5 See Figure 1 13
57. ilter 4 Install new oil filter Turn filter clockwise to install Hand tighten filter 1 2 to 3 4 turn after gasket contacts filter mount surface Refilling Oil Tank CAUTION Do not overfill oil tank Doing so can result in oil carryover to the air cleaner leading to equipment damage and or equipment malfunction 00190a 1 Refer to Table 1 2 Always use the proper grade of oil for the lowest expected air temperature before the next regu larly scheduled oil change Pour 2 0 quarts 1 9 liters of oil into engine oil tank 1 14 2008 Sportster Service Maintenance om00108 1 Thin oil film ONLY 2 Oil filter 3 Mounting plate Figure 1 7 Applying Thin Oil Film CAUTION Loosen clamp and pull plug from end of oil tank drain hose Allow a small amount of oil to flow from hose before reinstalling drain plug This removes air from the drain hose and reduces the possibility of oil pump cavitation 00560b 2 Install filler cap onto oil tank as described on previous page Make sure cap is fully seated 3 Startengine See Figure 1 8 Verify that oil pressure signal lamp turns off when engine speed is 1000 RPM or above Turn engine off 4 Check for oil leaks at oil filter and oil tank drain hose Check engine oil level See 1 5 ENGINE OIL AND FILTER Checking and Adding Oil earlier in this section sm01415 C0060 Figure 1 8 Oil Pressure Indicator Lamp BRAKES 1 6
58. lomar Kevlar Lexan Loctite Lubriplate Keps K amp N Mag naflux Marson Thread Setter Tool Kit MAXI fuse Molex MPZ Mulitilock Novus Packard Pirelli Permatex Philips PJ1 Pozidriv Robinair S100 Sems Snap on Teflon Threadlocker Torca Torco TORX Tufoil Tyco Ultratorch Velcro X Acto and XM Satellite Radio are among the trademarks of their respective owners H D MICHIGAN INC TRADEMARK INFORMATION Harley Harley Davidson H D Bar amp Shield Digital Tech Digital Technician Destroyer Deuce Dyna Electra Glide Evolution Fat Boy Glaze Gloss H D H Dnet com HD Harley Heritage Softail Heritage Springer Low Rider Night Rod Night Train Profile Revolution Road Glide Road King Rocker Softail Sportster Sun Ray Sunwash Tech Link Twin Cam 88 Twin Cam 88B Twin Cam 96 Twin Cam 96B Twin Cam 103 Twin Cam 103B Twin Cam 110 Twin Cam 110B Tour Pak Screamin Eagle Softail Super Guide Super Premium SYN3 Ultra Glide V Rod VRSC V Rod VRSC Wide Glide and Harley Davidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H D Michigan Inc CONTENTS All photographs illustrations and procedures may not neces sarily depict the most current model or component but are based on the latest production information available at the time of publication Since product improvement is our continual goal Harley Dav idson reserves the right to change specificatio
59. ngs Preformed Packings Always discard O rings after removal Replace with new O rings To prevent leaks lubricate the O rings before installation Apply the same type of lubricant as that being sealed Be sure that all gasket O ring and seal mating surfaces are thoroughly clean before installation Gears Always check gears for damaged or worn teeth Remove burrs and rough spots with a honing stone or crocus cloth before installation Lubricate mating surfaces before pressing gears on shafts Shafts If a shaft does not come out easily check that all nuts bolts or retaining rings have been removed Check to see if other parts are in the way before using force Shafts fitted to tapered splines should be very tight If shafts are not tight disassemble and inspect tapered splines Discard parts that are worn Be sure tapered splines are clean dry and free of burrs before putting them in place Press mating parts together tightly Clean all rust from the machined surfaces of new parts Part Replacement Always replace worn or damaged parts with new parts Exhaust System Leakage In the event of an exhaust system leak at a muffler or header pipe connection location disassemble and clean all mating surfaces Replace any damaged components If leak still exists disassemble and repair the leak by applying a bead of Harley Davidson High Performance Sealant Part No 99650 02 or an equivalent 02 Sensor Catalyst safe alterna
60. nk Do not fill oil tank to a level above upper mark on dipstick Replace filler cap CAUTION Do not overfill oil tank Doing so can result in oil carryover to the air cleaner leading to equipment damage and or equipment malfunction 001902 sm01413 1 Upper mark full 2 Lower mark add qt Figure 1 3 Oil Level Marks on Dipstick CHANGING OIL AND FILTER PART NUMBER TOOL NAME HD 42311 OR HD HARLEY DAVIDSON OIL FILTER 44067 A WRENCH General sm01673 Figure 1 4 Oil Filter Wrenches Completely drain oil tank of used oil at scheduled service intervals as specified in 1 8 MAINTENANCE SCHEDULE Refer to Table 1 3 Refill with fresh oil NOTES If vehicle is driven extremely hard used in competition or driven on dusty roads change engine oil at shorter inter vals Always change oil filter when changing engine oil Draining Oil Tank 1 Runengine until engine oil has reached normal operating temperature NOTE Oil will drain more quickly if filler cap dipstick is removed from oil tank 2 Remove oil filler cap dipstick from oil tank 3 See Figure 1 5 Place a suitable container directly under the drain hose 1 at the bottom rear of the engine crank case The container must be able to hold approximately 4 0 quarts 3 8 liters 4 Loosen worm drive clamp 2 and pull drain plug 3 from end of drain hose Completely drain engine oil from oil tank
61. ns equipment or designs at any time without notice and without incurring obligation MAINTENANCE 1 1 GENERAL Servicing a New Motorcycle eese 1 1 Safe Operating Maintenance eese 1 1 htc ccm p E 1 1 Repair pr m 1 1 RP EUT AE EE E E EE EE EA E E 1 1 Removing qo e 1 1 EI r E E E 1 1 Disassembly and Assembly 1 2 Checking Torques on Fasteners with Lock Patches 1 2 Magnetic Pans TEQVE aca 1 2 Repair and Replacement Procedures 1 2 Hardware and Threaded Parts 1 2 Threadlocking Agents rr mmt 1 2 Wri Hoses and LINES sacanear 1 2 Instruments and Gauges 1 2 co qo PPM 1 2 up 1 2 Cei Mem 1 2 Lip Bypass ed acad ca pra a EE d EAR AA E d 1 2 O Rings Preformed Packings 1 3 cite Lt ree TET 1 3 Me eat Sy cdi pelo Sia pt dec Na E ET 1 3 Pat FAQRUACONIIOIN METTI TEE MN E NIE 1 3 Exhaust System Leakage sess 1 3 ECC 1 3 Pait gie ei m 1 3 Cleaning Proces Siinses Plen RERUM TEE 1 3 Rust or Corrosion Remowval eese 1 3 Bearings etc 1 3 Ee IARE EO 1 3 ZU MOONS cci econ iioii iitod Pap cap paid utin hrec toto sacas 1 3 biduo ENTRE 1 3 Plieie Outtere Pry Dalee echec sicci deis ctbeto 1 3 UNI IT D C TT Lo 1 4 mier ONIE qe 1 4 BONING lt 5 custs iste tcp NRA
62. o thoroughly warm up this water will accumulate mix with the engine oil and form a sludge that is harmful to the engine MAINTENANCE SCHEDULE GENERAL If more detailed information is needed turn to the sections The table below lists the periodic maintenance requirements for Sportster model motorcycles If you are familiar with the procedures just refer to the table for the recommended service interval If necessary see the quick reference table Table 1 4 for the required specifications Table 1 3 Regular Service Intervals 2008 Sportster Models which follow for step by step instructions 1 3 Also throughout this manual you will be instructed to use various lubricants greases and sealants Refer to Table 1 5 for the correct part numbers of these items ITEM SERVICED PROCEDURE 1000 MI 5000 MI 10 000 MI 15 000MI 20 000MI 25 000 MI NOTES 1600 KM 8000 KM 16 000KM 24 000 KM 32 000 KM 40 000 KM Engine oil and filter Replace X X X X X X Oil lines and brake system Inspect for leaks X X X X X X 1 Air cleaner Inspect service as required X X X X X X Tires Check pressure inspect tread X X X X X X Wheel spokes Check tightness X X X X X X 1 4 Transmission lubricant Replace X X X Clutch Check adjustment X X X X X X 1 Primary chain Check adjustment X X X X X X Rear belt and sprockets Inspect adjust
63. priate thread chasing device and compressed air when using new or existing fasteners Always use the recommended threadlocking agent for your specific procedure 1 2 2008 Sportster Service Maintenance 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 Bearings Anti friction bearings must be handled in a special way To keep out dirt and abrasives cover the bearings as soon as they are removed from the package Wash bearings in a non flammable cleaning solution Knock out packed lubricant inside by tapping the bearing against a wooden block Wash bearings again Cover bearings with clean material after setting them down to dry Never use compressed air to dry bearings Coat bearings with clean oil Wrap bearings in clean paper When bearings are installed against shoulders be sure that the chamfered side of the bearing always faces the shoulder Lubricate bearings and all metal contact surfaces before pressing into place Only apply pressure on the part of the bearing that makes direct contact with the mating part Install bearings with numbered side facing out Always use the proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Only
64. r hardened steel parts can become magnetized when held in magnetic parts trays Metal fragments that would ordinarily be washed away in the oil and trapped in the oil filter or magnetic drain plug during vehicle operation could be cap tured by magnetized parts in the engine potentially causing accelerated engine wear and damage Parts that will be returned to service inside the vehicle s powertrain such as gears thrust washers and especially bearings should never be kept in magnetic parts trays 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 Threadlocking Agents Always follow specific service manual procedures when working with fasteners containing preapplied threadlocking agents when fastener replacement is recommended When re using fasteners containing threadlocking agents be sure to com pletely remove all existing threadlocking agent from fastener threads with a wire brush or wire wheel Also be sure to remove residual threadlocking agent from fastener hole using an appro
65. r approved eye protection when using striking tools Protect bystanders with approved eye protection Punches Chisels Never use a punch or chisel with a chipped or mush roomed end dress mushroomed chisels and punches with a file Hold a chisel or a punch with a tool holder if possible When using a chisel on a small piece clamp the piece firmly in a vise and chip toward the stationary jaw Wear approved eye protection when using these tools Protect bystanders with approved eye protection Screwdrivers Do not use a screwdriver for prying punching chiseling scoring or scraping Use the right type of screwdriver for the job match the tip to the fastener Do not interchange POZIDRIV PHILLIPS or REED AND PRINCE screwdrivers Screwdriver handles are not intended to act as insulation Do not use on live electrical circuits Do not use a screwdriver with rounded edges because it will slip Redress with a file 1 4 2008 Sportster Service Maintenance Ratchets and Handles Periodically clean and lubricate ratchet mechanisms with a light grade oil Do not replace parts individually ratchets should be rebuilt with the entire contents of service kit Never hammer or put a pipe extension on a ratchet or handle for added leverage Always support the ratchet head when using socket extensions but do not put your hand on the head or you may interfere with the action of its reversing mechanism When breaking loose a
66. r whenever brake lever pedal operation feels spongy Bleeding evacuates air from the system leaving only incom pressible hydraulic fluid CAUTION Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a NOTE Hydraulic brake fluid bladder type pressure equipment can be used to fill brake master cylinders through the bleeder valve Remove master cylinder reservoir cover so that system cannot pressurize Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and diaphragm in place BLEEDING FRONT BRAKE CAUTION D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b NOTES If D OT 4 brake fluid contacts painted surfaces IMMEDI ATELY flush area with clear water Cover handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir Spilling brake fluid on handlebar switches may render them inoperative 1 See Figure 1 9 Position motorcycle so t
67. roper 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 a 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 com ponent 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 per forming 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
68. s 3 88 Installing Upper Connecting Rod Bushings 3 90 Reaming Upper Connecting Rod Bushings 3 90 Honing Upper Connecting Rod Bushings 3 01 gir e 3 91 Assembly and Installation sees 3 91 3 20 CRANKCASE tur 3 92 ul jp luri N 3 92 ICT LOUP ET LT D cea tao LE 3 93 Fitting Piniom Bearg sasesana inona 3 95 Bearing SeleoctloFt si c eiicttiva a Er EA ie EXER ER Ra aka 3 05 Lapping Engine Main Bearing Races 99 Assembling Crankcase Halves sess 3 99 Vill TABLE OF CONTENTS 3 21 OIL PUMP c M E 3 100 Ripper Ma T Q 3 101 Diode oombl a niic obese ended iei acude d t bMS 3 101 Cleaning and Inspection seeeseeeeeeses 3 101 PBS pp eT E 3 101 lig Lol DP othe E RAP xk e bM MEE E ECKEN T EM EMG 3 101 3 22 OIL FILTER MOUNT PS TIT adde perdio ERE MERE Helge tu Spe band Ida 3 103 Disassembly 3 103 Gleaning and Inepection c accisoiscrsesnssevnsnniessrcgncnsesnedanseas 3 103 je s M 3 103 3 23 OIL TANK CO PIOS PROUD LP acusa ek tn pe tont dee EE RR S 3 104 FOImipugieiecsce caeci toot i vw cei aee d pM DR Od dst pA ie ter iide 3 104 liga at S BOT uic hein ceps to EE tert A sd UD EROR Pa EDI La 3 107 FUEL SYSTEM 4 1 SPECIFICATIONS FUEL SYSTEM
69. s before they reach the tread wear indicator bars NOTE Missing indicator wear bars represent less than 1 32 in 0 8 mm tread pattern depth remaining 3 Check for proper front and rear tire pressures when tires are cold Compare results against Table 1 9 Table 1 8 Tire Sizes 2008 Sportster Models MODEL MOUNT SIZE NUMBER XL 883 XL 883R XL 883L front 19 in D401F 100 90 19 XL 1200R XL 1200L XL 1200N XL 883C XL 1200C front 21 in D402F MH90 21 All rear 16 in D401 150 80B16 2008 vehicles use Dunlop Harley Davidson tires only Table 1 9 Tire Pressures 2008 Sportster Models MODEL LOAD TIRE PRESSURE COLD FRONT REAR PSI kPa PSI kPa All solo rider 30 206 36 248 rider and passenger 30 206 40 275 1 20 2008 Sportster Service Maintenance
70. s ic aa lai 7 49 7 22 REAR LIGHTING CONVERTER MODULE XL 1200N DOMESTIC ONLY EC ENTER 7 51 IP ST LL I en 7 51 Soya ESI Le g e RE RTT UTE 7 52 7 23 REAR STOP LAMP SWITCH EDDIE RESO TUE EET 7 53 Fe plein tt e 7 53 7 24 CRANK POSITION SENSOR CKP ET alse ee Ra tected ci nter ber dicem eu EAEE ei EIS ES 7 54 auicm 7 54 utes Mesi dedu mE RA TTE TRE 7 54 7 25 ALTERNATOR Removal and Disassembly esses 7 55 MeN oae N E rete EE EE e ATE 7 55 E E EI A TEO A LEE d e MEL E E 7 55 Cleaning and Inspections onr 7 56 Assembly and Installation cesses 7 56 PNUD sas cd sc vis Cae god ace ra p MN eee 7 56 PRO WOE T TP 7 57 Final T ue NETTE m 7 57 7 26 VEHICLE SPEED SENSOR VSS s dus EE E EE 7 58 PSU MNRE AE AA EEEE EEEE E I AR UU I EEE E 7 58 kastala Ione eea SR EMOTTURESS 7 58 TABLE OF CONTENTS XI TABLE OF CONTENTS 7 27 NEUTRAL SWITCH VEL a ETE TTE EOS 7 59 ROPICE Ig PT 7 59 7 28 MAIN WIRING HARNESS Deng ccc es etek oe ie I M in at i een 7 61 Removal oraria nean 7 61 instalation enia A E EVPE CDS EUR o qiOS 7 63 7 29 ELECTRICAL CADDIES ELM ESL NR EE E 7 67 Voltage Regulator Caddgy seeeesesesss 7 67 EEA usi ibis R A E PM 20s QS FIER Ore MIU MM 7 67 Deren a a cocti T po Rex T E Fa a EO tek on died 7 67 Wire IARMESS Cadi sc icsscsecccgacresmiactansarieavess mupimaciaanees 7 67 Beit Sass odere a ERU HAREREEA TER DUPERE
71. t 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 2008 Sportster Service Maintenance 1 1 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 Operate the vehicle to perform any final check or adjustments If all is correct the vehicle is ready to go back to the customer 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 Magnetic Parts Trays Magnetic parts trays are becoming common in the service facility because they are convenient and can keep parts from becoming lost during a repair procedure Howeve
72. ted Press down on filler cap until it snaps in place flush with top of oil tank cover sm03751 Figure 1 1 Filler Cap Dipstick Location 1 12 2008 Sportster Service Maintenance sm01412 1 Wide slot 2 Narrow slot Figure 1 2 Filler Cap Dipstick Checking Oil with Cold Engine 1 Position motorcycle so that it is leaning on jiffy stand on level ground 2 Remove filler cap See Removing and Replacing Oil Filler Cap above Wipe attached dipstick clean Reinstall oil filler cap in tank 3 Remove oil filler cap again and check oil level on dipstick See Figure 1 3 Dipstick has two marks If oil level is at or below lower mark 2 add only enough oil to bring the level to a point between the two arrows on the dipstick Replace filler cap Checking Oil with Warm Engine 1 Runengine until engine oil is at normal operating temper ature Turn engine off 2 Position motorcycle so that it is leaning on jiffy stand on level ground 3 Remove filler cap See Removing and Replacing Oil Filler Cap above Wipe attached dipstick clean Reinstall oil filler cap in tank 4 Remove filler cap again and check warm oil level on dip stick See Figure 1 3 Dipstick has two marks If oil level in tank is at or below lower mark add 1 0 quart 0 946 liter of Harley Davidson oil to tank Replace filler cap 5 If you added oil in step 4 remove filler cap and verify cor rect engine oil level in oil ta
73. tive Reassemble components wipe off any excess sealant and allow adequate curing time following sealant product instructions before oper ating vehicle CLEANING Part Protection Before cleaning protect rubber parts such as hoses boots and electrical insulation from cleaning solutions Use a grease proof barrier material Remove the rubber part if it cannot be properly protected Cleaning Process Any cleaning method may be used as long as it does not result in parts damage Thorough cleaning is necessary for proper parts inspection Strip rusted paint areas to bare metal before priming and repainting Rust or Corrosion Removal Remove rust and corrosion with a wire brush abrasive cloth sand blasting vapor blasting or rust remover Use buffing crocus cloth on highly polished parts that are rusted Bearings Remove shields and seals from bearings before cleaning Clean bearings with permanent shields and seals in solution WARNING Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b Clean open bearings by soaking them in a petroleum cleaning solution Never use a solution that contains chlorine Let bearings stand and dry Do not dry with compressed air Do not spin bearings while they are drying TOOL SAFETY Air Tools Always use approved eye protection equipment when performing any task using air operated tools On
74. vos er a denen vU p pH sd 4 26 IGNI NN ERO Eo too a 4 26 MISES SRI Cuna Oc E va E REFER SAM ER p ERI EA CEU A E E 4 26 4 11 EXHAUST SYSTEM EINE I MI IRR A AE EE E T dee 4 28 PROIMO VE M T 4 29 Mufflers and Exhaust Pipes tian 4 29 Muffler Interconnect Bracket 4 29 THEN ON oso aca Re RD TTE 4 30 Muffler Interconnect Bracket ss 4 30 Exhaust Pipes and Mufflers 4 30 4 12 FUEL INJECTORS 1 e T 4 32 REMOVA asses arcu a resa Sg ER OCCR ER Fa RAF Ren Uo IK aet cad 4 32 gir rir p 4 33 4 13 FUEL PUMP CLIE 4 35 FONG uc Mete URP mL URN 4 35 Disassembly e rr orti ew Ere EXER t vRS E pUIY eens 4 36 Pressure Regulator and Filter Housing 4 36 Fuel Pump Assembly and Pump Bracket 4 37 Low Fuel Level Sensor Assembly 4 37 Fuel Pump Sender Harness sss 4 37 PA SPU fe 4 37 Fuel Pump Sender Harness sss 4 37 Low Fuel Level Sensor Assembly 4 37 Fuel Pump Assembly and Pump Bracket 4 37 Pressure Regulator and Filter Housing 4 37 HAS TAN HOM MNT OLD 4 38 4 14 FUEL PRESSURE TEST I ERN ER T T 4 40 Hg 4 40 4 15 INTAKE LEAK TEST ETSI ES NR
75. y Charger eeseeeeesss 1 45 Battery Installation and Connection 1 46 TABLE OF CONTENTS TABLE OF CONTENTS ilt 1 47 1 17 SPARK PLUGS gr m 1 49 li M eis 1 49 Spark Plug Cable Inspection rennes 1 49 1 18 STEERING HEAD BEARINGS PO USIIMON e T 1 51 Hg m 1 51 1 19 REAR FORK BEARINGS i r t 1 53 aile s NS Mew 1 53 1 20 FRONT FORK OIL COMICO OILS E TIERE 1 54 Ranging Pork OIL earings ERO VES Qu OUS 1 54 Filling Fork Oil Forks Assembled in Frame 1 54 Filling Fork Oil Forks Disassembled out of Frame 1 55 1 21 CABLE AND CHASSIS LUBRICATION LEE BE P NE S EE E A A E 1 56 Cables and Hand L66r6 uisi tcr epa nis 1 56 Foot Shift Lever and Rear Brake Pedal 1 56 Jilfy SHAG ios iie ten co es cepi d M cH x dp Ra carta EAE 1 56 Steering Head Bearings sss 1 56 1 22 AIR CLEANER AND EXHAUST SYSTEM General RO E REUTERS 1 57 emo val cis voten rp Dar E bee Unique te dm E 1 57 Cleaning Inspection and Repair sssssss 1 58 We AN 1 58 Exhaust System Leak Check uueuss 1 58 1 23 THROTTLE CONTROL Cable Inspection and Lubrication 1 59 Cable AGUSTI na ass ciis ER a aE 1 59
76. y know evaluate or advise the service trade of all possible ways in which service might be performed or of the possible hazardous con sequences of each method we have not undertaken any such broad evaluation Accordingly anyone who uses a service procedure or tool which is not recommended by Harley Dav idson must first thoroughly satisfy himself that neither his nor the operator s safety will be jeopardized as a result Failure to do so could result in death or serious injury PRODUCT REFERENCES WARNING Read and follow warnings and directions on all products Failure to follow warnings and directions can result in death or serious injury 00470b When reference is made in this manual to a specific brand name product tool or instrument an equivalent product tool or instrument may be substituted Kent Moore Products All tools mentioned in this manual with an HD J or B preface must be ordered through SPX Kent Moore For ordering II FOREWORD information or product returns warranty or otherwise visit WWW Spx com Loctite Sealing and Threadlocking Products Some procedures in this manual call for the use of Loctite products If you have any questions regarding Loctite product usage or retailer wholesaler locations please contact Loctite Corp at www loctite com PRODUCT REGISTERED MARKS Allen Amp Multilock Bluetooth Brembo Delphi Deutsch Dunlop Dynojet Fluke G E Versilube Gunk Hydroseal Hy

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