HARLEY-DAVIDSON XL883N User Manual

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2008.5 Sportster Models Owner's Manual: Safety First

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Safety First

Safe Operating Rules: Sportster Models

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Motorcycles are different from other vehicles. They operate, steer, handle and brake differently. Unskilled or improper use could result in loss of control, death or serious injury. (00556c)

● Take a rider training course.

● Read Owner's Manual before riding, adding accessories or servicing.

● Wear a helmet, eye protection and protective clothing.

● Never tow a trailer.

Before operating your new motorcycle it is your responsibility to read and follow the operating and maintenance instructions in this manual, and follow these basic rules for your personal safety.

● Know and respect the rules of the road (see RULES OF THE ROAD section). Carefully read

and observe the rules contained in the RIDING TIPS booklet accompanying this Owner's Manual. Read and familiarize yourself with the contents of the MOTORCYCLE HANDBOOK for your state.

● Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls,

correct fuel and oil supply.

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)

● Use only Harley-Davidson approved parts and accessories. Use of certain other

manufacturer's performance parts will void your new motorcycle warranty. See your HarleyDavidson dealer for details.

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2008.5 Sportster Models Owner's Manual: Safety First

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)

When refueling your motorcycle, the following rules should be observed.

● Refuel in a well ventilated area with the engine turned off.

● Remove fuel filler cap slowly.

● Do not smoke or allow open flames or sparks when refueling or servicing the fuel system.

● Do not fill fuel tank above the bottom of the filler neck insert.

● Leave air space to allow for fuel expansion.

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. (00004f)

Do not run motorcycle in a closed garage or confined area. Inhaling motorcycle exhaust, which contains poisonous carbon monoxide gas, could result in death or serious injury. (00005a)

The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result in death or serious injury. (00006a)

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2008.5 Sportster Models Owner's Manual: Safety First

Be sure jiffy stand is fully retracted before riding. If jiffy stand is not fully retracted, it can contact the road surface causing a loss of vehicle control, which could result in death or serious injury. (00007a)

● A new motorcycle must be operated according to the special break-in procedure. See

Break-in Riding Rules.

● Operate motorcycle only at moderate speed and out of traffic until you have become

thoroughly familiar with its operation and handling characteristics under all conditions.

NOTE:

We recommend that you obtain information and formal training in the correct motorcycle riding technique. In the United States, the Motorcycle Safety Foundation

offers beginning and advanced

rider safety courses. Call (949)727-3227 for information.

Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive speed can cause loss of vehicle control, which could result in death or serious injury. (00008a)

● Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce

speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control.

● Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be

subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement, rough road surfaces, rider control error, etc. These forces may influence the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar. This may aggravate an unstable condition.

● Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize

the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of the vehicle and do not load bulky items too far behind the rider or add weight to the handlebars or front forks. Do not exceed maximum specified load in each saddlebag.

NOTE:

New riders should gain experience under various conditions while driving at moderate speeds.

● Operate your motorcycle defensively. Remember, a motorcycle does not afford the same

protection as an automobile in an accident. One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns left into the on-coming motorcyclist. Operate only with headlamp on.

● Wear an approved helmet, clothing, and foot gear suited for motorcycle riding. Bright or

light colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.

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2008.5 Sportster Models Owner's Manual: Safety First

Avoid contact with exhaust system and wear protective clothing that completely covers legs while riding. Exhaust pipes and mufflers get very hot when engine is running and remain too hot to touch, even after engine is turned off. Failure to wear protective clothing could result in burns or other serious injury. (00009a)

● When carrying passengers, it is your responsibility to instruct them on proper riding

procedures. (See Riding Tips for Motorcyclist included in your Harley-Davidson Owner's Kit.)

● Do not allow other individuals, under any circumstances, to operate your motorcycle unless

you know they are experienced, licensed riders and are thoroughly familiar with the operation of your particular motorcycle.

● Protect your motorcycle against theft. After parking your motorcycle, lock the steering head

and remove ignition key from switch. Set security alarm if present.

● Safe motorcycle operation requires alert mental judgment combined with a defensive

driving attitude. Do not allow fatigue, alcohol or drugs to endanger your safety or that of others.

● Vehicles equipped with a sound system should have the volume adjusted to a

nondistracting level before operating vehicle.

● Maintain your motorcycle in proper operating condition in accordance with Regular Service

Intervals: 2008 Sportster Models. Particularly important to motorcycle stability is proper

tire inflation pressure, tread condition, and proper adjustment of wheel bearings and steering head bearings.

Do not operate vehicle with forks locked. Locking the forks restricts the vehicle's turning ability, which could result in death or serious injury. (00035a)

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)

Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Harley-Davidson dealer for repairs. Loose, worn or damaged steering or suspension components can adversely affect stability and handling, which could result in death or serious injury. (00011a)

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2008.5 Sportster Models Owner's Manual: Safety First

Regularly inspect shock absorbers and front forks. Replace leaking, damaged or worn parts that can adversely affect stability and handling, which could result in death or serious injury. (00012a)

Use Harley-Davidson replacement fasteners. Aftermarket fasteners can adversely affect performance, which could result in death or serious injury. (00013a)

● See a Harley-Davidson service manual for proper torque values.

● Aftermarket fasteners may not have the specific property requirements to perform properly.

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a HarleyDavidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00015a)

Do not exceed the motorcycle's Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR). Exceeding these weight ratings can affect stability and handling, which could result in death or serious injury. (00016e)

● GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of

the rider, passenger and cargo that can be safely carried.

● GAWR is the maximum amount of weight that can be safely carried on each axle.

● The GVWR and GAWR are shown on the information plate which is located on the frame

down tube.

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2008.5 Sportster Models Owner's Manual: Safety First

Do not tow a disabled motorcycle. Towing can adversely affect stability and handling, which could result in death or serious injury. (00017a)

Do not pull a trailer with a motorcycle. Pulling a trailer can cause tire overload, reduced braking efficiency and adversely affect stability and handling, which could result in death or serious injury. (00018b)

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 attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (00019e)

Wheel weights on wheels without spokes contain lead and lead compounds, chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. (00356d)

Consult a Harley-Davidson dealer regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so can aggravate an initial problem, cause costly repairs, cause an accident and could result in death or serious injury. (00020a)

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2008.5 Sportster Models Owner's Manual: Safety First

● Be sure all equipment required by federal, state and local law is installed and in good

operating condition.

Rules of the Road

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● Keep to the right side of the road centerline when meeting other vehicles coming in the

opposite direction. Ride to left of center of your lane to avoid oily pavement ahead.

● Always sound your horn, actuate your turn signals, and exercise caution when passing

other vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up or down a hill.

● At street intersections give the right-of-way to the vehicle on your right. Do not presume

you have the right-of-way, as the other driver may not know it is your turn.

● Always signal when preparing to stop, turn or pass.

● All traffic signs, including those used for the control of traffic at intersections, should be

obeyed promptly. SLOW DOWN signs near schools and CAUTION signs at railroad crossings should always be observed and your actions governed accordingly.

● When intending to turn to the left, signal at least 100 feet 30.5 meters before reaching the

turning point. Move over to the centerline of the street (unless local rules require otherwise), slow down, enter the intersection of the street and then turn carefully to the left.

● Never anticipate a traffic light. When a change is indicated from GO to STOP (or vice versa)

in the traffic control systems at intersections, slow down and wait for the light to change. Never run through a yellow or red traffic light.

● While turning either right or left, watch for pedestrians, animals, as well as vehicles.

● Do not leave the curb or parking area without signaling. Be sure your way is clear to enter

moving traffic. A moving line of traffic always has the right-of-way.

● Be sure your license plate is installed in the position specified by law and is clearly visible at

all times. Keep the plate clean.

● Ride at a safe speed that is consistent with the type of highway you are on. Pay strict

attention to whether the road is dry, oily, icy or wet.

● Watch for debris such as leaves or loose gravel.

● Weather and traffic conditions on the highway dictate adjusting your speed and driving

habits accordingly.

Accessories and Cargo

Top of page

Harley-Davidson Motor Company cannot test and make specific recommendations concerning every accessory or combination of accessories sold. Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying additional weight.

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2008.5 Sportster Models Owner's Manual: Safety First

See the Accessory and Cargo section in your Owner's Manual. Improper loading of cargo or installation of accessories can affect motorcycle stability and handling, which could result in death or serious injury. (00021a)

● GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of

the rider, passenger and cargo that can be safely carried.

● GAWR is the maximum amount of weight that can be safely carried on each axle.

● The GVWR and GAWR are shown on the information plate which is located on the frame

down tube.

Accessory and Cargo Guidelines

The following guidelines should be used when equipping a motorcycle, carrying passengers and/or cargo.

● Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce

speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control.

● Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be

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2008.5 Sportster Models Owner's Manual: Safety First

This may aggravate an unstable condition.

● Keep cargo weight concentrated close to the motorcycle and as low as possible. This

minimizes the change in the motorcycle's center of gravity.

● Distribute weight evenly on both sides of the vehicle.

● Do not load bulky items too far behind the rider or add weight to the handlebars or front

forks.

● Do not exceed maximum specified load in each saddlebag.

● Luggage racks are designed for lightweight items. Do not overload racks.

● Be sure cargo is secure and will not shift while riding and recheck the cargo periodically.

Accessories that change the operator's riding position may increase reaction time and affect handling of the motorcycle.

● Additional electrical equipment may overload the motorcycle's electrical system possibly

resulting in electrical system and/or component failure.

The front and/or rear guard(s) can provide limited leg and cosmetic vehicle protection under unique circumstances. (Fall over while stopped, very slow speed slide.) It is not made or intended to provide protection from bodily injury in a collision with another vehicle or any other object. (00022a)

Large surfaces such as fairings, windshields, back rests, and luggage racks can adversely affect handling. Only genuine Harley-Davidson items designed specifically for the motorcycle model should be used with proper installation.

Only Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a)

Noise Control System

Top of page

Tampering

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2008.5 Sportster Models Owner's Manual: Safety First

Owners are warned that removal or replacement of any noise control system component may be prohibited by law. This prohibition applies prior to vehicle sale or delivery to the ultimate purchaser. Use of a vehicle on which noise control system components have been removed or rendered inoperative may also be prohibited by law.

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2008.5 Sportster Models Owner's Manual: Identification

Owner's Manuals Print Close Window

Identification

Vehicle Identification Number (V.I.N.): Sportster Models

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General

See V.I.N. Locations: Sportster Models. The full 17-digit V.I.N. is stamped on the steering head and printed on a label located on the right front frame down tube.

See

Typical Harley-Davidson V.I.N.: 2008 Sportster Models. A unique 17-digit serial or Vehicle

Identification Number (V.I.N.) is found on each motorcycle. For a description of each item in the V.I.N., refer to

Harley-Davidson V.I.N. Breakdown: 2008 Sportster Models.

Abbreviated V.I.N.

An abbreviated V.I.N. is stamped on the left side of the crankcase between the front and rear cylinders.

Example: CV38111000

See

Typical Harley-Davidson V.I.N.: 2008 Sportster Models for the complete V.I.N. for the

same motorcycle as it appears on the steering head.

NOTE:

Always give the full 17-digit Vehicle Identification Number when ordering parts or making any inquiry about your motorcycle.

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2008.5 Sportster Models Owner's Manual: Identification

1. Stamped V.I.N.

2. V.I.N. label

V.I.N. Locations: Sportster Models

Typical Harley-Davidson V.I.N.: 2008 Sportster Models

Harley-Davidson V.I.N. Breakdown: 2008 Sportster Models

POSITION DESCRIPTION POSSIBLE VALUES

1 Market designation 1=Originally manufactured for sale within the United States

5=Originally manufactured for sale outside of the United States

2 Manufacturer HD=Harley-Davidson

3 Motorcycle type 1=Heavyweight motorcycle (901 cc or larger)

4=Middleweight motorcycle (351 cc to 900 cc)

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2008.5 Sportster Models Owner's Manual: Identification

4 Model See V.I.N. model table

5 Engine type

2=Evolution

883 cc air-cooled, fuel-injected

3=Evolution

1200 cc air-cooled, fuel-injected

3=Evolution

1200 cc precision-cooled, fuel-injected

6 Introduction date 1=Regular

2=Mid-year

3=California/regular

4=Cosmetic changes and/or special introductory date

5=California/cosmetic changes and/or special introductory date

6=California/mid-year

7 V.I.N. check digit Can be 0-9 or X

8 Model year 8=2008

9 Assembly plant K=Kansas City, MO U.S.A.

10 Sequential number Varies

V.I.N. Model Codes: 2008 Sportster Models

CODE MODEL CODE MODEL

XL 883 Sportster

883

XL 1200R Sportster® 1200 Roadster

XL 883C Sportster

883 Custom

XL 1200L Sportster® 1200 Low

XL 883L Sportster

883 Low

XL 1200N Sportster® 1200 Nightster™

XL 883R Sportster

883R

XR 1200 Sportster® 1200

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2008.5 Sportster Models Owner's Manual: Identification

XL 1200C Sportster

1200 Custom

Labels

Top of page

See Labels: Sportster Models for safety and maintenance labels which were on the vehicle when new. If removed, replacement labels may be purchased for your motorcycle. Refer to

Labels:

Sportster Models for label descriptions.

Labels: Sportster Models

LABEL PART NUMBER DESCRIPTION LOCATION

1 15368-01A Battery warning Top of belt guard (XR

1200)

Front left of rear fork (XL models)

2 29466-08 General warnings (XR 1200) Top of left side cover

3 29127-95B General warnings (XL models except

883R/1200N)

Top of air cleaner cover

4 29404-01A General warnings (XL 883R/1200N) Top of air cleaner cover

5 13699-08 Fuse block label (XR 1200) Inside left side cover

6 13571-07 Fuse block label (XL models) Inside left side cover

7 15376-06 Battery removal/installation Inside left side cover

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2008.5 Sportster Models Owner's Manual: Identification

Labels: Sportster Models

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2008.5 Sportster Models Owner's Manual: Specifications

Owner's Manuals Print Close Window

Specifications

Specifications: 2008 Sportster Models

Top of page

Engine: 2008 XL Sportster Models

ITEM

XL 883

MODELS

XL 1200

MODELS

Number of cylinders

Type 4-cycle, 45 degree

V-Type, air cooled

Compression ratio 8.9-1 9.7-1

Bore 3.00 in. 76.20 mm3.50 in. 88.90

Stroke 3.81 in. 96.77 mm3.81 in. 96.77

Displacement 53.86

cu. in.

883 cc 73.20

cu. in.

1200 cc

Torque 55.0 ft-

lbs

@ 3500 RPM

74.6 Nm

@ 3500 RPM

79.1 ftlbs

@ 4000 RPM

107.3 Nm

@ 4000 RPM

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2008.5 Sportster Models Owner's Manual: Specifications

Engine: 2008 XR 1200 Model

ITEM SPECIFICATION

Number of cylinders 2

Type 4-cycle, 45 degree

V-Type, precision cooled

Compression ratio 10.0-1

Bore 3.50 in. 88.90 mm

Stroke 3.81 in. 96.82 mm

Displacement 73.41 cu. in. 1203 cc

Torque (World) 74.1 ft-lbs

@ 3500 RPM

100.5 Nm

@ 3500 RPM

NOTE:

Specifications in this publication may not match those of official certification in some markets due to timing of publication printing, variance in testing methods, and/or vehicle differences. Customers seeking officially recognized regulatory specifications for their vehicle should refer to certification documents and/or contact their respective dealer or distributor.

Ignition System: 2008 Sportster XL Models

COMPONENT SPECIFICATION

Ignition timing not adjustable

Battery 12 volt, 12 amp/hr,

sealed and maintenance free

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2008.5 Sportster Models Owner's Manual: Specifications

Spark plug type 10-6R12

Spark plug size 12 mm

Spark plug gap 0.038-0.043 in. 0.97-1.09 mm

Spark plug torque 12-18 ft-lbs 16.3-24.4 Nm

Ignition System: 2008 Sportster XR 1200 Model

COMPONENT SPECIFICATION

Ignition timing not adjustable

Battery 12 volt, 12 amp/hr,

sealed and maintenance free

Spark plug type 10R12X

Spark plug size 12 mm

Spark plug gap 0.035 in. 0.89 mm

Spark plug torque 12-18 ft-lbs 16.3-24.4 Nm

Transmission: 2008 Sportster Models

TRANSMISSION SPECIFICATION

Type Constant mesh, foot shift

Speeds 5 forward

Sprocket Teeth: 2008 Sportster Models

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2008.5 Sportster Models Owner's Manual: Specifications

DRIVE ITEM

NUMBER OF TEETH

XL 883 MODELS XL 1200 MODELS XR 1200

U.S.

MODELS

WORLD

MODELS

U.S.

MODELS

WORLD

MODELS

WORLD

MODELS

Primary Engine 34 38 38 38 34

Clutch 57 57 57 57 57

Final Transmission 28 28 29 30 28

Rear wheel 68 68 68 68 68

Overall Gear Ratios: 2008 Sportster Models

GEAR

XL 883 MODELS XL 1200 MODELS XR 1200

U.S.

MODELS

WORLD

MODELS

U.S.

MODELS

WORLD

MODELS

WORLD

MODELS

1st 10.782 10.782 9.315 9.004 10.782

2nd 7.702 7.702 6.653 6.432 7.702

3rd 5.728 5.728 4.948 4.783 5.728

4th 4.748 4.748 4.102 3.965 4.748

5th 4.071 4.071 3.517 3.400 4.071

Tire Sizes: 2008 Sportster Models

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2008.5 Sportster Models Owner's Manual: Specifications

MODEL MOUNT SIZE NUMBER

XR 1200 front 18 in. D502F 120/70 ZR 18

XR 1200 rear 17 in. D502 180/55 ZR 17

XL 883, XL 883R, XL 883L,

XL 1200R, XL 1200L, XL 1200N

front 19 in. D401F 100/90-19

XL 883C, XL 1200C front 21 in. D402F MH90-21

All XL models rear 16 in. D401 150/80B16

2008 vehicles use Dunlop Harley-Davidson tires only.

Tire Pressures: 2008 Sportster Models

MODEL LOAD

TIRE PRESSURE (COLD)

FRONT REAR

PSI kPa PSI kPa

XL models solo rider 30 206 36 248

rider and passenger 30 206 40 275

XR 1200 solo rider 36 248 38 262

rider and passenger 36 248 42 290

Bulb Chart: 2008 Sportster Models

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2008.5 Sportster Models Owner's Manual: Specifications

LAMP

DESCRIPTION

(ALL LAMPS 12 VOLT)

BULBS

REQUIRED

CURRENT DRAW

(AMPERAGE)

HARLEYDAVIDSON

PART NUMBER

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 1.75 68163-84

Instrument panel Illuminated with LEDs. Replace entire assembly upon failure.

*Functions as turn signals, tail lamps and brake lamps on 1200N model.

Dimensions: 2008 Sportster XL 883 Models

ITEM

XL 883

XL 883R

XL 883C

CUSTOM

XL 883L

LOW

IN. MM IN. MM IN. MM

Wheel base 60.0 1524 60.4 1534.2 60.0 1524

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2008.5 Sportster Models Owner's Manual: Specifications

Overall length 90.1 2288.5 90.3 2293.6 90.1 2288.5

Overall width 32.7 830.6 32.7 830.6 35.2 894.1

Road clearance 5.6 141 4.4 111.8 3.9 99.1

Overall height* 45.7 1160.8 45.7 1160.8 45.7 1160.8

Saddle height** 27.3 693.4 26.5 673 25.4 645.2

*XL 883R overall height is 44.8 in. 1137.9 mm .

**With 180 lb. 81.6 kg rider on seat.

Dimensions: 2008 Sportster 1200 Models

ITEM

XL 1200C

CUSTOM

XL 1200R

ROADSTER

XL 1200L

LOW

XL 1200N

NIGHTSTER

XR 1200

IN. MM IN. MM IN. MM IN. MM IN. MM

Wheel base 60.4 1534.2 60.0 1524.0 59.7 1516.4 60.0 1524.0 59.8 1518.9

Overall length 90.3 2293.6 90.1 2288.5 89.1 2263.1 85.8 2179.3 85.4 2169.2

Overall width 32.7 830.6 36.7 932.2 35.2 894.1 36.4 924.6 36.5 927.1

Road clearance 4.4 111.8 5.6 141.0 4.4 111.8 3.9 99.1 5.8 147.3

Overall height 45.7 1160.8 49.2 1249.7 46.8 1188.7 43.6 1107.4 45.1 1145.5

Saddle height* 26.5 673.1 28.1 713.7 26.3 668.0 25.3 642.6 29.2 741.7

*With 180 lb. 81.6 kg rider on seat.

Capacities: 2008 Sportster XL 883 Models

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ITEM

XL 883

XL 883R

XL 883C

CUSTOM

XL 883L

LOW

U.S. LITERS U.S. LITERS U.S. LITERS

Fuel tank

(total)

3.3 gal. 12.5 4.5 gal. 17.0 3.3 gal. 12.5

Oil tank with filter 2.8 qt. 2.65 2.8 qt. 2.65 2.8 qt. 2.65

Transmission

(approximate)

32 oz. 0.95 32 oz. 0.95 32 oz. 0.95

Low fuel warning

light on

0.8 gal. 3.0 1.0 gal. 3.8 0.8 gal. 3.0

Capacities: 2008 Sportster 1200 Models

ITEM

XL 1200C

CUSTOM

XL 1200R

ROADSTER

XL 1200L

LOW

XL 1200N

NIGHTSTER

XR 1200

U.S. LITERS U.S. LITERS U.S. LITERS U.S. LITERS U.S. LITERS

Fuel tank

(total)

4.5

gal.

17.0 4.5 gal.

17.0 3.3 gal.

12.5 3.5 gal.

13.25

Oil tank

with filter

2.8 qt.

2.65 2.8 qt.

2.65

Transmission

(approximate)

32 fl.

oz.

0.95 32 fl. oz.

0.95

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Low fuel warning

light on

1.0

gal.

3.8 0.8 gal.

3.0 1.0 gal.

3.8 0.8 gal.

3.0 0.8 gal.

3.0

Weights: 2008 Sportster XL 883 Models

ITEM

XL 883

XL 883C

CUSTOM

XL 883L

LOW

XL 883R

LB. KG LB. KG LB. KG LB. KG

Weight

(as shipped from factory)

563 255 565 256 563 255 568 258

GVWR 1000 454 1000 454 1000 454 1000 454

GAWR front 335 152 335 152 335 152 335 152

GAWR rear 665 302 665 302 665 302 665 302

Weights: 2008 Sportster 1200 Models

ITEM

XL 1200C

CUSTOM

XL 1200R

ROADSTER

XL 1200L

LOW

XL 1200N

NIGHTSTER

XR 1200

LB. KG LB. KG LB. KG LB. KG LB. KG

Weight (as shipped from factory)

562 255 565 256 557 253 545 247 562 254.9

GVWR 1000 454 1000 454 1000 454 1000 454 1000 454

GAWR front 335 152 335 152 335 152 335 152 335 152

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GAWR rear 665 302 665 302 665 302 665 302 665 302

Tire Data

Top of page

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)

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)

Tubeless tires fitted with the correct size inner tubes may be used on all Harley-Davidson laced (wire spoked) wheels. Protective rubber rim strips must be used with tubeless tires (fitted with correct size inner tubes) when mounted on laced (wire spoked) wheels.

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)

Tubeless tires are used on all Harley-Davidson cast and disc wheels.

Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube.

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Harley-Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00026a)

Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Harley-Davidson approved replacement tires. (00090b)

See

Specifications: 2008 Sportster Models for tire pressures and sizes.

Gasoline Blends

Top of page

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.

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 and as much as 15% MTBE. Gasoline/MTBE blends can be used in your motorcycle.

● ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline.

Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%.

● REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term

used to describe gasoline blends that are specifically designed to burn cleaner than other

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types of gasoline, leaving fewer tailpipe emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of gas and Harley-Davidson recommends you use it when possible, as an aid to cleaner air in our environment.

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

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

Fuel

Top of page

Refer to Octane Ratings. Always use a good quality unleaded gasoline. Octane ratings are usually found on the pump.

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)

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)

Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making air entrapment and pressurization a possibility.

Octane Ratings

SPECIFICATION RATING

Pump Octane (R+M)/2 91 (95 RON)

Catalytic Converters

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Top of page

All international (HDI) and destination Japan model motorcycles are equipped with catalytic converters.

Do not operate catalytic converter-equipped vehicle with engine misfire or a non-firing cylinder. If you operate the vehicle under these conditions, the exhaust will become abnormally hot, which can cause vehicle damage, including emission control loss. (00149a)

Use only unleaded fuel in catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150b)

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2008.5 Sportster Models Owner's Manual: Controls and Indicators

Owner's Manuals Print Close Window

Controls and Indicators

General: Controls and Indicators

Top of page

Read the CONTROLS AND INDICATORS section before riding your motorcycle. Failure to understand the operation of the motorcycle could result in death or serious injury. (00043a)

Some features explained are unique to certain models. These features may be available as accessories for your Harley-Davidson motorcycle. See a Harley-Davidson dealer for a complete list of accessories that will fit your specific motorcycle.

Sportster XL 1200N Model

Top of page

See Sportster XL 1200N Model. Unlike all other Sportster models, the XL 1200N is equipped with a convertible side-mounted license plate assembly, which includes an LED-illuminated license plate

lamp module. See a Harley-Davidson dealer for LED replacement.

The license plate assembly must be in the extended position during operation. Due to local regulations, this feature may not be found in all destinations.

The standard rear fender-mounted tail lamp assembly common to all other Sportster models is not present on the XL 1200N. Instead, the rear turn signals also function as tail lamps and brake lamps.

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1. Convertible side-mount license plate assembly

2. Rear turn signal lamp (also functions as tail/brake lamp)

Sportster XL 1200N Model

Ignition/Headlamp Key Switch: Sportster Models

Top of page

The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b)

See

Ignition/Headlamp Key Switch: Sportster Models. The ignition/headlamp key switch

controls electrical functions of the motorcycle.

See the YOUR OWNER'S MANUAL section at the front of this book. Be sure to record all your key numbers in the space provided.

Protect your vehicle against theft. After parking your motorcycle, lock the steering head and remove ignition key from switch. Failure to lock your motorcycle may result in theft and/or equipment damage. (00151a)

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Do not operate vehicle with forks locked. Locking the forks restricts the vehicle's turning ability, which could result in death or serious injury. (00035a)

Do not lubricate barrel locks with petroleum based lubricants or graphite. Inoperative locks may result. (00152a)

Turn key counterclockwise to remove from the ignition. Refer to

Ignition/Headlamp Switch

Positions: 2008 Sportster Models for all key switch functions.

NOTES:

● ACC-Accessories and hazard warning flasher can be turned on. Instrument lamps are on.

Brake lamp and horn can be activated. Key may not be removed.

● The lamps work when the switch is in the IGNITION position, as required by law in some

localities.

1. Ignition off

2. Accessory ON (ACC.)

3. Ignition ON

Ignition/Headlamp Key Switch: Sportster

Models

Ignition/Headlamp Switch Positions: 2008 Sportster Models

LOCATION AND OPERATION SWITCH POSITION FUNCTION

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Switch is on right side of steering neck.

Push in and turn key to operate.

OFF Ignition and lamps are off. Key may

be removed.

ACC* Accessories and hazard warning

flasher can be turned on. Instrument lamps are on. Brake lamp and horn can be activated. Key may be removed except for international models.

IGNITION* Ignition and lamps are on.

*International models have an additional function - position lamp and tail lamp are also on.

Hand Controls: Basic Operation

Top of page

Electric Starter Switch

NOTE:

Off/Run switch MUST be in RUN position to operate engine.

See

Handlebar Controls. The electric starter switch is located on the right handlebar control group.

See

Starting the Engine: Sportster Models for detailed operation procedures.

1. Put the engine off/run switch in the RUN position and the transmission in neutral. Neutral (green) indicator lamp should be illuminated.

2. See

Ignition/Headlamp Key Switch: Sportster Models. Turn ignition/headlamp key

switch to IGNITION and push the START switch to operate starter motor.

Engine OFF/RUN Switch

See Handlebar Controls. The engine off/run switch (7) turns the ignition power ON or OFF. The engine off/run switch is located on the right handlebar control. Push the top portion of the engine

off/run switch to turn off ignition power and shut the engine off. Push the bottom portion of the engine off/run switch to turn on ignition power.

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NOTES:

● The engine off/run switch must be in the RUN position to start or operate the engine.

● The engine off/run switch should be used to shut the engine off.

1. To shut the engine off, push the top of the off/run switch to the ignition OFF position.

2. See

Ignition/Headlamp Key Switch: Sportster Models. Turn the ignition key to the OFF

position to turn the ignition power completely OFF.

Throttle Control Grip

See Handlebar Controls. The throttle control grip (9) is located on the right handlebar control and is operated with the right hand.

To reduce rider fatigue on long trips, a spring loaded throttle friction adjustment screw (10) is located at the bottom of the throttle grip clamp on non-cruise equipped models.

1. Slowly turn throttle control grip clockwise (toward the front of the bike) to close the throttle (decelerate).

2. Slowly turn throttle control grip counterclockwise (toward rear of bike) to open the throttle (accelerate).

Do not tighten throttle friction adjustment screw to the point where the engine will not return to idle automatically. Over-tightening can lead to loss of vehicle control, which could result in death or serious injury. (00031b)

3. Unscrew the throttle friction adjustment screw so the throttle returns to the idle position when the hand is removed from the grip.

4. Screw the throttle adjustment screw in to increase friction on grip. This provides a damping effect on throttle motion.

NOTE:

The throttle friction adjustment screw should not be used under normal stop and go operating conditions.

Clutch Hand Lever

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Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a)

See

Handlebar Controls. The clutch hand lever (1) is located on the left handlebar and is operated

with the fingers of the left hand.

1. Slowly pull clutch hand lever in against handlebar grip to fully disengage clutch.

2. Shift to first gear using the gear shifter lever. See

Shifting Gears.

3. Slowly release the clutch hand lever to engage clutch.

A clutch switch is incorporated into the left handlebar switch assembly. It enables the rider to start the vehicle in any gear (or in neutral) as long as the clutch lever is pulled in. If the clutch is not disengaged, the vehicle will not start.

Horn Switch

See Handlebar Controls. The horn is operated by pushing on the horn switch (2) located on the left handlebar control group.

Headlamp Dimmer Switch

See Handlebar Controls. The headlamp dimmer switch (3) is located on the left handlebar. The switch has two positions to activate the headlamps high or low beams.

● Press the top of the headlamp dimmer beam switch to activate the high beam.

● Press the bottom of the headlamp dimmer switch to return to the low beam.

See Indicator Lamps. The (blue) high beam indicator lamp will illuminate when the high beam is on.

Turn Signal Switches

See Handlebar Controls. Each handlebar control group contains a turn signal switch.

● The right turn signal switch (11) operates the right front and right rear flashing lamps.

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● The left turn signal switch (4) operates the left front and left rear flashing lamps.

NOTE:

Front turn signal lamps also function as running lamps (except International models).

1. Clutch hand lever

2. Horn switch

3. Headlamp dimmer switch

4. Left turn signal switch

5. Master cylinder reservoir

6. Electric starter switch

7. Engine off/run switch

8. Brake hand lever

9. Throttle control grip

10. Throttle friction adjusting screw

11. Right turn signal switch

Handlebar Controls

Turn Signal Switch Operation

Top of page

The turn signal switches are used by the turn signal module to control turn signal operation based on vehicle speed, vehicle acceleration and turn completion.

Momentarily depress the desired turn signal switch. The turn signal lamps will begin and continue flashing until they are manually or automatically cancelled. As long as the motorcycle is stationary, the signals will flash.

NOTES:

● If you are signaling to turn in one direction and you depress the switch for the opposite turn

signal, the first signal is cancelled and the opposite side begins flashing.

● If you want to stop the lamps from flashing, briefly depress the turn signal switch a second

time. The turn signal lamps will stop flashing.

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Hazard Warning 4-Way Flasher

Top of page

Use the following method to activate the four-way flashers.

1. With the ignition key ON and security system disarmed (if equipped), press the left and right turn signal switches at the same time.

2. Turn the ignition key OFF and arm the security system if present and desired. The four-way flashers will continue for two hours.

3. To cancel four-way flashing, disarm the security system if necessary, turn the ignition key ON and press the left and right turn signal switches at the same time.

This system allows a stranded vehicle to be left in the four-way flashing mode and secured until help is found.

Indicator Lamps

Top of page

See Indicator Lamps. Five indicator lamps are provided.

● The green TURN indicators will flash when turn signals are activated; therefore, flashing

indicates the chosen turn direction. When the 4-way hazard flashers are operating, both turn indicators will flash simultaneously.

● The blue BEAM indicator lamp, when lit, signals high beam headlamp operation.

● The green NEUTRAL lamp, when lit, signals the transmission is in neutral gear.

● The red OIL indicator lamp, when lit, signals that oil is not circulating through the engine.

NOTE:

The OIL indicator lamp will glow when the ignition is turned on prior to starting engine. With engine running, lamp should be off when engine speed is above idle.

Several other circumstances that could cause the red oil indicator lamp to signal, include the following:

● If the oil pressure indicator lamp does not go off at speeds above idling, it is usually because

of an empty oil tank or diluted oil.

● In freezing weather the oil feed may clog with ice and sludge, preventing oil circulation.

● A grounded oil signal switch wire.

● A faulty signal switch.

● A damaged or improperly installed check valve.

● Trouble with the pump.

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If the oil pressure indicator lamp remains lit, always check the oil supply first. If the oil supply is normal and the lamp is still lit, stop the engine at once and do not ride further until the trouble is located and the necessary repairs are made. Failure to do so may result in engine damage. (00157a)

1. Left turn

2. High beam

3. Neutral

4. Oil

5. Right turn

Indicator Lamps

Instruments: Sportster Models

Top of page

Speedometer

See

Speedometer/Odometer: XL 1200C Sportster 1200 Custom, Speedometer/Odometer and Tachometer: XL 1200R Sportster 1200 Roadster, and Speedometer/Odometer and Tachometer: XR 1200 Model. The speedometer registers miles per hour (U.S. models) or

kilometers per hour (international models) of forward speed. The speedometer also provides the following selectable functions:

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● Odometer

● Trip odometers A and B

● 12 or 24 hour clock

The speedometer has a single display window for the above functions.

1. See Speedometer/Odometer: XL 1200C Sportster 1200 Custom,

Speedometer/Odometer and Tachometer: XL 1200R Sportster 1200 Roadster, and Speedometer/Odometer and Tachometer: XR 1200 Model. Pressing the function

switch (on back of speedometer) with the ignition switch in any position will activate the odometer reading and time. Time and mileage or kilometers may be checked without unlocking ignition switch. Press and release function switch (on back of speedometer) once to view odometer. Press and release button again to display time.

2. To check mileage on trip odometers, the ignition switch must be in the ACC or IGNITION position. Press and release the function switch (on back of speedometer) until the desired trip odometer reading is displayed. An A or B in the upper left of the display window identifies trip odometers.

3. To reset or zero trip odometers, have desired (A or B) odometer in display window. Press function switch (on back of speedometer) and hold button for 2-3 seconds. The trip odometer will be reset to zero.

4. Repeat the previous step if you wish to zero both trip odometers.

Setting Clock

1. Turn the ignition switch to ACC or IGNITION.

2. See Speedometer/Odometer: XL 1200C Sportster 1200 Custom,

Speedometer/Odometer and Tachometer: XL 1200R Sportster 1200 Roadster, and Speedometer/Odometer and Tachometer: XR 1200 Model. Press and release function

switch (on back of speedometer) until time (hour and minutes) is displayed. Press and hold the function switch for five seconds or until 12HR begins to blink in the speedometer display window. Release the button.

3. Press and release the function switch (on back of speedometer) once to advance to a blinking 24HR military style time display. Each time you press and release the button, the display will switch between 12HR and 24HR.

4. When the desired time style is displayed, press and hold the function switch (on back of speedometer) for five seconds. The display will switch to the time display with the hours blinking.

5. Press and release the button repeatedly to advance the hours. Each time you press and release the button, the display will advance one hour.

NOTE:

No AM or PM time setting is required. When the correct hour is reached, press and hold function switch to advance to minute setting.

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6. When the correct hour is displayed, press and hold the button for five seconds. The minutes display will start blinking.

7. Press and release the button repeatedly to advance the minutes display. Each time you press and release the button, the display will advance one minute.

8. When the correct minutes are displayed, press and hold the button for five seconds. The minutes display will stop blinking, indicating that the clock has been set.

9. Turn the ignition switch OFF.

Tachometer

See OPERATING RECOMMENDATIONS section. Do not operate the engine above maximum safe RPM as shown under OPERATION (red zone on tachometer). Lower the RPM by upshifting to a higher gear or reducing the amount of throttle. Failure to lower RPM may cause equipment damage. (00159a)

The tachometer (if applicable) registers the engine speed in revolutions per minute (RPM).

Tip Indicator Lamp

If tip occurs, check all controls for proper operation. Restricted control movement can adversely affect the performance of the brakes, clutch or ability to shift, which could result in loss of vehicle control and death or serious injury. (00350a)

Should motorcycle be tipped over, the word "tip" will appear in the odometer window. Engine will not start until reset. To reset, cycle ignition/headlamp key switch ON-OFF-ON.

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1. Speedometer

2. Function switch (back of gauge)

3. Security system lamp

4. Odometer/trip odometer

5. Battery lamp

6. Low fuel indicator

7. Check engine lamp

Speedometer/Odometer: XL 1200C

Sportster 1200 Custom

1. Speedometer

2. Function switch (back of gauge)

3. Tachometer

4. Security system lamp

5. Odometer/trip odometer

6. Battery lamp

7. Low fuel indicator

8. Check engine lamp

Speedometer/Odometer and Tachometer:

XL 1200R Sportster 1200 Roadster

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1. Speedometer

2. Function switch (back of gauge)

3. Tachometer

4. Check engine lamp

5. Low fuel indicator

6. Battery lamp

7. Odometer/trip odometer

8. Security system lamp

Speedometer/Odometer and Tachometer:

XR 1200 Model

Gear Shift Lever

Top of page

The clutch must be fully disengaged before attempting a gear shift. Failure to fully disengage the clutch can result in equipment damage. (00182a)

See

Shift Pattern: Sportster Models. The gear shift lever is located on the left side of the

motorcycle and is operated with the left foot. The transmission is a five speed sequential gear box.

1. Push the gear shift lever all the way down (full stroke) to shift the transmission to the next lower gear.

2. Lift the gear shift lever all the way up (full stroke) to shift the transmission to the next higher gear.

NOTES:

❍ Release the gear shift lever after each gear change. ❍ The lever must return to its central position before another gear change can be

made.

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First gear is the last gear position that can be found by pushing the gear shift lever full stroke downward.

Neutral is located between first and second gear. The green neutral indicator lamp on the dash will illuminate when the transmission is in neutral.

To shift from first gear to neutral, lift the gear shift lever 1/2 of its full stroke.

When the motorcycle is standing still and the engine is not running, shifting gears requires a different technique. Before shifting in this condition, move the motorcycle backward and forward with the clutch fully disengaged (clutch lever pulled in). While maintaining slight pressure on the shift lever, shift from one gear to another.

Even with the engine running and the motorcycle standing still, difficulty may be experienced in shifting gears. This difficulty occurs because transmission gears are not turning and shifting parts are not lined up to permit engagement.

When difficulty of shifting gears is experienced, do not under any circumstances, attempt to force the shift. The results of such abuse will be a damaged or broken shifter mechanism. (00161a)

See

Shifting Gears for more information.

Shift Pattern: Sportster Models

Brake System

Top of page

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2008.5 Sportster Models Owner's Manual: Controls and Indicators

Do not apply brake strongly enough to lock the wheel. A locked wheel will skid and can cause loss of vehicle control, which could result in death or serious injury. (00053a)

The rear brake pedal controls the rear wheel brake and is located on the motorcycle's right side. Operate the rear brake pedal with the right foot.

The front brake hand lever controls the front wheel brake and is located on the right handlebar. Operate the hand lever with the fingers of the right hand.

Brakes should be applied uniformly and evenly to prevent wheels from locking up. A balance between rear and front braking is generally best.

Jiffy Stand

Top of page

Always park motorcycle on a level, firm surface. An unbalanced motorcycle can fall over, which could result in death or serious injury. (00039a)

The jiffy stand is located on the left side of the motorcycle and swings outward to support the motorcycle for parking.

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Rear View Mirrors

Top of page

Objects in mirrors are closer than they appear. Use caution when judging distance of objects in mirrors. Failure to judge correct distances could result in death or serious injury. (00033a)

Your vehicle is equipped with two convex rear view mirrors.

This type of mirror is designed to give a much wider view to the rear than a flat mirror. However, cars and other objects seen in this type of mirror will look smaller and farther away than they actually are.

● Use caution when judging the size or relative distance of objects seen in rear view mirrors.

● Always adjust the rear view mirrors to clearly reflect the area behind the motorcycle before

riding.

NOTE:

Adjust mirrors so you can see a small portion of your shoulders in each mirror. This will help you establish the relative distance of vehicles to the rear of your motorcycle.

Fuel Filler Cap: Sportster Models

Top of page

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General

See SAFE OPERATING RULES section and review safety procedures listed below.

Do not spill fuel onto the motorcycle while refueling. Immediately wipe up fuel spills on your motorcycle. Fuel can cause damage to cosmetic surfaces. (00147b)

Use only unleaded fuel in catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150b)

Do not use aftermarket fuel caps. Aftermarket fuel caps may fit improperly and leak, which could lead to death or serious injury. See a Harley-Davidson dealer for approved fuel caps. (00034a)

XL Models

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See Fuel Filler Cap: Sportster XL Models. To open, turn fuel filler cap counterclockwise and lift up. To close, turn fuel filler cap clockwise until it clicks. The ratchet action of the cap prevents

overtightening.

NOTE:

Fuel filler cap turns approximately a 3/4 turn before it starts unscrewing.

XR 1200 Model

See Fuel Filler Cap: XR 1200 Model. To open fuel filler cap, pull metal tab up, turn tab counterclockwise and remove cap. To close, insert fuel filler cap, turn tab clockwise and push tab

down.

Fuel Filler Cap: Sportster XL Models

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Fuel Filler Cap: XR 1200 Model

Fork Lock: Sportster Models

Top of page

See

Fork Lock Location: Sportster Models. Sportster models have the fork lock located on the

steering head just above the ignition/headlamp key switch. Using the fork lock immediately after parking your motorcycle will discourage unauthorized use or theft when parking your motorcycle.

Do not operate vehicle with forks locked. Locking the forks restricts the vehicle's turning ability, which could result in death or serious injury. (00035a)

To lock fork, see

Fork Lock Positions: Sportster Models.

1. Turn fork to full left position.

2. Insert ignition key into fork lock.

3. Turn to right position (clockwise).

4. Remove ignition key.

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Fork Lock Location: Sportster Models

1. Fork locked

2. Fork unlocked

Fork Lock Positions: Sportster Models

Shock Absorber Preload Adjustment: Sportster Models

Top of page

See Rear Shock Absorber Adjustment: Sportster Models. The rear shock absorber spring preload can be adjusted for the weight the motorcycle is to carry. Increase preload to accommodate

additional weight of rider, passenger and/or luggage. Reduce preload if carrying less weight.

NOTE:

See Preload Adjustment: Sportster Models. The shock absorber has either three or five different preload positions, depending on the motorcycle model.

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Be sure both shock absorbers are adjusted to same preload position. Improper adjustment can adversely affect stability and handling, which could result in death or serious injury. (00036a)

See

Spanner Wrench. To adjust the rear shock spring preload, turn spring adjusting cam to the

desired position with a SPANNER WRENCH HD-94820-75A . When reducing preload, cam should be rotated in opposite direction.

See

Right Side Preload Adjustment: XR 1200 Model. On the XR 1200 model, use SPANNER

WRENCH HD-48645 with a 3/8-inch ratchet and extension to adjust the preload on the right side of the motorcycle.

The 883 Low and 1200N are designed for solo operation. If you choose to add an adult passenger and/or cargo to the vehicle, the ride quality will be compromised. See a Harley-Davidson dealer for high capacity rear suspension options. (00487e)

1. Rear shock absorber

2. Adjusting cam preload

Rear Shock Absorber Adjustment:

Sportster Models

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Spanner Wrench

1. Spanner wrench (HD-48645)

2. 3/8-in. extension

Right Side Preload Adjustment: XR 1200

Model

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1. Minimum preload adjustment

2. Maximum preload adjustment

Preload Adjustment: Sportster Models

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2008.5 Sportster Models Owner's Manual: Harley-Davidson Smart Security System

Owner's Manuals Print Close Window

Harley-Davidson Smart Security System

Top of page

Components

See Security Module w/Antenna (shown removed). The Harley-Davidson Smart Security System (H-DSSS) consists of a Hands-Free Security Module (HFSM) (1) and a Hands-Free

Antenna (2) mounted on the motorcycle, and a Hands-Free Fob carried by the rider/passenger.

After parking the motorcycle, turn the ignition key to OFF and the Smart Security System will automatically arm within five seconds. While armed, the starter and ignition are disabled and the rider may leave the motorcycle knowing that the module will activate an alarm if someone tampers with the ignition or attempts to move the motorcycle.

If the fob is present, the module will automatically disarm when the ignition key is turned to IGNITION or ACCESS.

NOTE:

Do not relocate the module or the antenna on the motorcycle.

Options

Several options are available for the Harley-Davidson Smart Security System from the HarleyDavidson Genuine Motor Accessories and Motor Parts catalog. Options include:

● Smart Siren and Smart Siren II.

● Security Pager and Security Pager Receiver II.

● Replacement Fobs.

See a Harley-Davidson dealer for details.

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1. Hands-Free Security Module

2. Hands-Free Antenna

Security Module w/Antenna (shown

removed)

FCC Regulations

Top of page

FCC ID: L2C0027TR IC ID: 3432A-0027TR

FCC ID: L2C0028TR IC ID: 3432A-0028TR

This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada rules. Operation is subject to the following two conditions:

(1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation.

WARNING: Changes or modifications not expressively approved by the party responsible for compliance could void the user's authority to operate the equipment.

The term "IC:" before the radio certification number only signifies that Industry Canada technical specifications were met.

Hands-Free Fob

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Top of page

Fob Assignment

See Hands-Free Fob: Smart Security System. Hands-Free Fobs are electronically assigned to the Harley-Davidson Smart Security System by a Harley-Davidson dealer so that the module can

recognize a fob's unique signal. Only two fobs can be assigned to the module at any one time.

Replacement fobs can be purchased from a dealership but can only be assigned to the motorcycle by a trained Harley-Davidson technician.

NOTES:

● The reusable label found on the fob packaging lists the serial number of the fob. For

reference, fix the label to a blank "NOTES" page in the Owner's Manual.

● The serial number of the fob is also found on the inside of the fob. See Fob Battery.

● The module will arm only if the fob has been assigned by a Harley-Davidson dealer and a

Personal Identification Number (PIN) has been entered in the system. The PIN should be recorded on the Personal Information page in the front of this Owner's Manual and on the removable wallet card.

● Should the rider misplace the fob or if the fob fails, the rider can refer to the wallet card

and use the PIN to manually disarm the system. Refer to

Arming and Disarming and

Fob Battery.

● The PIN can easily be changed by the rider at any time. Refer to Personal Identification

Number (PIN).

Hands-Free Fob: Smart Security System

Riding with a Fob

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● Always carry the fob when riding, loading, fueling, moving, parking or servicing the

motorcycle. Carry the fob in a convenient pocket.

● Do not leave the fob attached to the handlebars or store the fob in a saddlebag or Tour-

Pak

. Unintentionally leaving the fob with the motorcycle when it's parked prevents the

system from activating the alarm.

● Do not ride with the fob stored in a metal case or with the fob closer than 3.0 in. 76 mm

to a cell phone, PDA, display or other electronic device. Any electromagnetic interference may prevent the fob from disarming the system.

● For added security, always lock the fork and remove the ignition key when parked. If the

fob is within range and the motorcycle is unlocked, tampering with the motorcycle will not activate the alarm.

Personal Identification Number (PIN)

Top of page

The Personal Identification Number (PIN) is a number that can be used to disarm the HarleyDavidson Smart Security System in case an assigned fob is misplaced, fails or if the fob and module cannot communicate because of electromagnetic interference.

A PIN is a five-digit number (1-9, no zeros).

Changing the PIN

To maintain security, the rider can change the PIN at any time. Refer to Changing the PIN.

Changing the PIN

STEP

NO.

ACTION WAIT FOR CONFIRMATION NOTES

1 Select a 5-digit (1 thru 9)

PIN and record on the wallet card from Owner's Manual.

2 With an assigned fob

present, turn IGN key

IGNITION-OFF- IGNITION-OFF- IGNITION.

3 Press left turn signal

switch 3 times.

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4 Press right turn signal

switch 1 time and release.

Turn signals will flash 3 times. Current PIN will appear in odometer. The first digit will be flashing.

See figure showing the odometer window with PIN display.

5 Enter first digit (a) of new

PIN by pressing left turn signal switch a times.

6 Press right turn signal

switch 1 time and release.

The new digit (a) will replace the current in odometer window.

7 Enter second digit (b) of

new PIN by pressing left turn signal switch b times.

8 Press right turn signal

switch 1 time and release.

The new digit (b) will replace the current in odometer window.

9 Enter third digit (c) of new

PIN by pressing left turn signal switch c times.

10 Press right turn switch 1

time and release.

The new digit (c) will replace the current in odometer window.

11 Enter fourth digit (d) of

new PIN by pressing left turn signal switch d times.

12 Press right turn switch 1

time and release.

The new digit (d) will replace the current in odometer window.

13 Enter fifth digit (e) of new

PIN by pressing left turn signal switch e times.

14 Press right turn switch 1

time and release.

The new digit (e) will replace the current in odometer window.

15 Before the module rearms,

turn the ignition key to OFF.

The odometer will return to mileage. Turning the ignition

key to OFF stores the new PIN in the module.

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1. Current PIN (example) on PIN Change

2. PIN Disarm

Odometer Windows - PIN

Security Status Indicator

Top of page

See Security Status Indicator. The illuminated key icon in the speedometer face indicates the status of the Harley-Davidson Smart Security System.

● Armed: A key icon that blinks approximately every 3 seconds indicates that the system is

armed.

● Disarmed: After the ignition/headlamp switch is turned to IGNITION and the system

disarms, the key icon will remain illuminated for approximately four seconds and then turn off.

● Service: A key icon that remains illuminated longer than four seconds indicates that

service of the module is required.

Security Status Indicator

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Arming and Disarming

Top of page

Arming

When the motorcycle is parked and the ignition key is turned to OFF, the Harley-Davidson Smart Security System arms automatically within five seconds if no motion is detected. Even when the fob is present, the system will arm.

On arming, the turn signals will flash twice and the optional siren will chirp twice. While armed, the key icon in the speedometer face will flash every three seconds.

NOTE:

International Models: The HFSM must be in the Chirp Mode for the siren to chirp on arming or on disarming. See

Siren Chirp Mode (Confirmation).

Disarming

Once disarmed, the rider may ride or move the motorcycle for parking, storage or service without setting off the alarm.

Fob: An armed Smart Security System is automatically disarmed when the ignition key is turned to IGNITION with the fob present.

When the module disarms, the optional siren will chirp once and the key icon will illuminate for a solid four seconds and then turn off.

NOTE:

Any motion, like lifting the motorcycle up off of its jiffy stand, or turning the ignition key to IGNITION and the module will electronically "poll" for the presence of the fob. If the fob is present, the system disarms.

Personal Identification Number (PIN): If the fob is misplaced or if the present fob fails to communicate with the module, the system can be disarmed with the Personal Identification Number (PIN).

Disarming with a PIN

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Do not turn handlebars, straddle seat or lift motorcycle off the jiffy stand. During a PIN disarm, if the Smart Security System detects motorcycle motion the system will activate the alarm.

Entering a PIN to Disarm Harley-Davidson Smart Security System

STEP

NO.

ACTION WAIT FOR CONFIRMATION NOTES

1 If necessary, verify the

current 5-digit PIN.

Should be recorded on wallet card.

2 Turn ignition key to

IGNITION.

3 Quickly (within 2 seconds of

turning ignition key) hold both turn signal switches in until confirmation.

Key icon flashes at fast rate. In the odometer window, a flashing dash will be followed by four more dashes.

See figure showing the odometer window with PIN display. Five dashes will appear in the odometer window.

4 Enter first digit (a) in the

PIN by pressing left turn switch a times.

The first digit (a) in the odometer will be the first digit in the PIN.

5 Press right turn switch 1

time.

The first digit is stored and the dash will flash.

Serves as enter key.

6 Enter second digit (b) in

the PIN by pressing left turn switch b times.

The second digit (b) in the odometer will be the second digit in the PIN.

7 Press right turn switch 1

time.

The second digit is stored and the next dash will flash.

Serves as enter key.

8 Enter third digit (c) in the

PIN by pressing left turn switch c times.

The third digit (c) in the odometer will be the third digit in the PIN.

9 Press right turn switch 1

time.

The third digit is stored and the next dash will flash.

Serves as enter key.

10 Enter fourth digit (d) in the

PIN by pressing left turn switch d times.

The fourth digit (d) in the odometer will be the fourth digit in the PIN.

11 Press right turn switch 1

time.

The fourth digit is stored and the next dash will flash.

Serves as enter key.

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12 Enter fifth digit (e) in the

PIN by pressing left turn switch e times.

The fifth digit (e) in the odometer will be the fifth digit in the PIN.

13 Press right turn switch 1

time.

The fifth digit is stored. The key icon stops blinking.

Smart Security System is disarmed.

NOTES:

● At any time during a PIN disarm, if the fob is brought within range of the motorcycle, the

Smart Security System will disarm when the module receives the coded signal from the fob.

● If a mistake is made while entering PIN, wait two minutes before another disarming

attempt.

● The Smart Security System will remain disarmed until the ignition key is turned to OFF.

Arming with Hazard Warning 4-Way Flashers On

If it should be necessary to leave a motorcycle parked along side a roadway, the hazard warning four-way flashers can be turned ON and the Smart Security System armed.

1. Turn ignition key to ACCESS.

2. Simultaneously press both left and right turn signal switches to turn the four-way flashers ON.

3. Turn the ignition key to OFF to arm the Smart Security System.

To turn hazard warning flashers OFF, turn the ignition key to IGNITION and simultaneously press the left and right turn signal switches.

Alarm

Top of page

Warnings

Once armed, if the motorcycle is moved or lifted up off of its jiffy stand or if the ignition key is turned to IGNITION and the fob is not present, the alarm will warn the operator with three alternate flashes of the turn signals and a chirp of the optional siren.

Within four seconds, if the motorcycle is back on its jiffy stand and no further motion is detected

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and/or the ignition key is turned to OFF, the module will remain armed without activating the alarm.

If the motorcycle motion continues or the ignition key is not turned back to OFF, the module will issue a second warning four seconds after the first.

NOTE:

During warnings and alarms, the starter motor and the ignition circuits are disabled.

The Alarm

If the Smart Security System is still detecting motion and/or if the ignition key has not been turned back to OFF after a second warning, the system will activate the alarm.

When activated, the Smart Security System will:

● Alternately flash the four turn signals.

● See Optional Smart Siren. Sound the optional siren.

Duration: The alarm will stop within 30 seconds and if no motion is detected, the alarm will not restart.

However, if motorcycle motion continues the system will repeat the 30 second alarm and recheck for motion. The alarm will repeat this 30 second alarm cycle for five minutes (10 cycles) or until the alarm is deactivated.

NOTE:

The alarm will also activate the LED, vibration or audible modes of a Harley-Davidson Security Pager. A pager can operate either in silent or in combination with an optional Smart Siren. The range of a pager can be up to 0.5 mile (0.8 km). See a Harley-Davidson dealer for details.

Optional Smart Siren

Deactivate the Alarm

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Key Fob: Bring the fob to the motorcycle. After the module identifies that the fob is present, the system will terminate the alarm.

Siren Chirp Mode (Confirmation)

Top of page

Chirpless Mode

In the chirpless mode, the siren does not chirp on arming or disarming.

NOTE:

Even when armed in the chirpless mode, the siren still chirps warnings on movement and will activate the alarm through cycles.

Chirp Mode

On arming in the chirp mode, the siren responds with two chirps. When disarming, the siren responds with a single chirp.

Switching Modes

Cycling quickly through two armings and disarmings will switch the system from either the chirpless mode or the chirp mode to its opposite.

1. With the fob present, the Ignition Switch to ON and the system disarmed, turn the Ignition Switch OFF.

2. When the system arms (2 flashes of turn signals), immediately turn the Ignition Switch to ON.

3. Wait until the security lamp goes out, then immediately turn the Ignition Switch OFF.

4. When the system arms (2 flashes of turn signals), immediately turn the Ignition Switch to ON and wait for system to disarm.

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Transport Mode

Top of page

It is possible to arm the security system without enabling the motion detector for one ignition cycle. This allows the vehicle to be picked up and moved in an armed state, however, any attempt to start the engine will trigger the alarm.

To Enter Transport Mode

1. Turn the Ignition Switch to IGNITION.

2. Set the Engine Stop Switch to OFF.

3. With an assigned fob within range, turn the Ignition Switch from IGNITION to ACC.

4. Simultaneously press both the left and the right turn signal switches. This must be done within five seconds of turning the Ignition Switch to ACC.

5. After the turn signals flash once, turn the Ignition Switch to OFF and the module is armed.

6. Confirmation: Turn signal blinks three times when armed for one ignition cycle.

To Exit Transport Mode

Return the system to normal operation:

With the fob present, turn the Ignition Switch to IGNITION to disarm the HFSM. To cancel the transport mode, set the Engine Stop Switch to RUN.

Storage and Service Departments

Top of page

Long Term Parking

To maintain arming, store the fob beyond the range of the module. If the motorcycle is to be

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moved while parked, have the fob present.

If the motorcycle will not be operated for several months, such as during the winter season, follow the Owner's Manual instructions for storage. Refer to Motorcycle Storage.

Service Departments

When the motorcycle is to be left at a Harley-Davidson dealer, there are two options:

1. Leave an assigned fob with the dealer.

2. To maintain possession of the fob, ask the dealer to disable the module for service (service mode) before leaving the dealership.

Fob Battery

Top of page

Replacing the Battery

Replace the key fob battery every year.

1. See Hands-Free Fob Battery. Slowly turn a thin blade in the thumbnail slot (1) on the side of the fob to separate the two halves.

2. Remove the battery (2) and discard.

NOTE:

Dispose of the old battery in accordance with local regulations.

3. Install a new battery (Panasonic 2032 or equivalent) with the positive (+) side down.

4. Align the two halves of the fob and snap together.

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1. Thumbnail slot

2. Battery

3. Fob serial number

Hands-Free Fob Battery

Power Disconnects

Top of page

Optional Siren

On a power disconnect, to prevent the module from actuating the optional siren:

1. Verify that the fob is present.

2. Turn the ignition key to IGNITION.

3. Pull the main fuse from its holder or disconnect the battery.

Troubleshooting

Top of page

Key Icon

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If the system key icon stays illuminated while riding, see a Harley-Davidson dealer.

Fob

With the fob present, if the Smart Security System continues to actuate warnings and alarms, one of the following can be the cause:

1. Electromagnetic Interference: Other electronic devices, power lines, or other electromagnetic sources can cause the Smart Security System to operate inconsistently.

a. Verify that the fob is not in a metal enclosure or within 3.0 in. 76 mm of any other

electronic devices.

b. Place the fob on the seat and turn the ignition key to IGNITION. After the module

disarms, return the fob to a convenient location.

c. Move motorcycle at least 15 feet 5 m from the spot of interference.

2. Discharged Fob Battery: Use the PIN to disarm the module. Replace the battery. Refer to

Fob Battery.

3. A Damaged Fob: Use the PIN to disarm the motorcycle. Replacement fobs are available for purchase from a Harley-Davidson dealer.

Siren

● If the siren does not chirp two or three times on a valid arming command from the

security module, the siren is either in the Chirpless Mode, not connected, not working, or the siren wiring was opened or shorted while the siren was disarmed.

● If the siren is armed and the internal siren battery is dead, shorted, disconnected, or has

been charging for a period longer than 24 hours, the siren will respond with three chirps on arming instead of two.

● The internal siren battery may not charge if the vehicle's battery is less than 12.5 volts.

● If the siren enters the self-driven mode where it is powered from the siren's internal 9 volt

battery, the turn signal lamps may or may not alternately flash. If the security module activates the siren, the turn signal lamps will alternately flash. If the siren has been armed and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20 to 30 seconds and then turn off for 5 to 10 seconds. This alarm cycle will be repeated ten times if the siren is in the self-driven mode.

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2008.5 Sportster Models Owner's Manual: Operation

Owner's Manuals Print Close Window

Operation

Operating Recommendations: Sportster Models

Top of page

Motorcycles are different from other vehicles. They operate, steer, handle and brake differently. Unskilled or improper use could result in loss of control, death or serious injury. (00556c)

● Take a rider training course.

● Read Owner's Manual before riding, adding accessories or servicing.

● Wear a helmet, eye protection and protective clothing.

● Never tow a trailer.

Do not run the engine at extremely high RPM with clutch disengaged or transmission in neutral. Running an engine at high RPM can result in engine damage. (00177a)

Do not exceed the maximum safe RPM specified below under any conditions. Exceeding the maximum safe engine RPM can result in equipment damage. (00248a)

● The maximum recommended safe engine speed is 6000 RPM.

● Do not idle engine unnecessarily for more than a few minutes with motorcycle standing still.

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If motorcycle will not be ridden for a period of three weeks or more with security system armed, it is recommended to connect a Battery Tender to maintain battery charge. If security system will not be armed, it is recommended that the 30 amp maxi-fuse be removed. See Electrical Protection:

Sportster Models.

Air-cooled engines require air movement over the cylinders and heads to maintain proper operating temperature. Extended periods of idling or parade duty can overheat the engine, resulting in serious engine damage. (00178a)

An engine running long distances at high speed must be given closer than ordinary attention to avoid overheating and possible engine damage.

NOTE:

Have the engine checked regularly and keep it well tuned.

This applies particularly to a motorcycle equipped with windshield and fairing.

When riding on wet roads, brake efficiency and traction are greatly reduced. Failure to use care when braking, accelerating or turning on wet roads can cause loss of control, which could result in death or serious injury. (00041a)

NOTE:

When descending upon a long, steep grade, downshift and use engine compression together with intermittent application of both brakes to slow the motorcycle.

Continuous use of brake causes overheating and reduced efficiency, which could result in death or serious injury. (00042a)

Do not coast for long distances with the engine off or idling. The transmission is properly lubricated only when the engine is running. Coasting long distances can result in transmission damage. (00180b)

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Do not tow a disabled motorcycle. Towing can adversely affect stability and handling, which could result in death or serious injury. (00017a)

Break-in Riding Rules

Top of page

The First 500 Miles (800 Kilometers)

The sound design, quality materials, and workmanship that are built into your new Harley-Davidson will give you optimum performance right from the start.

To allow your engine to wear in its critical parts, we recommend that you observe the riding rules provided below for the first 500 miles 800 kilometers . Adherence to these suggestions will help to assure good future durability and performance.

1. During the first 50 miles 80 kilometers of riding, keep the engine speed below 4000 RPM in any gear. Do not lug the engine by running or accelerating at very low RPM, or by running at high RPM longer than needed for shifting or passing.

NOTE:

For models without a tachometer, operate the motorcycle according to the speeds given in Upshift (Acceleration) Gear Speeds and Downshift (Deceleration) Gear Speeds

during motorcycle break-in.

2. Up to 500 miles 800 kilometers , vary the engine speed and avoid operating at any steady engine speed for long periods. Engine speed up to 5000 RPM in any gear is permissible.

3. Drive slowly and avoid fast starts at wide open throttle until the engine has warmed up.

4. Avoid lugging the engine by not running the engine at very low speeds in higher gears.

5. Avoid hard braking. New brakes need to be broken-in by moderate use for the first 200 miles 300 kilometers .

Pre-Riding Checklist

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Read the CONTROLS AND INDICATORS section before riding your motorcycle. Failure to understand the operation of the motorcycle could result in death or serious injury. (00043a)

Before riding your motorcycle at any time, make a general inspection to be sure it is in safe riding condition.

1. Verify fuel is present in tank and add fuel if required.

2. Adjust mirrors to proper riding positions.

3. Verify oil is present in oil tank.

4. Check controls to make sure they operate properly. Operate the front and rear brakes, throttle, clutch and shifter. All controls should operate freely without binding.

5. Check steering for proper operation by turning the handlebars through the full operating range. Handlebars should turn smoothly without binding.

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6. Check tire condition and pressure. Incorrect pressure will result in poor riding characteristics and can affect handling and stability. Refer to tire specifications for correct inflation pressure to use.

Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b)

7. Check all electrical equipment and switches including the headlamp, stop lamp, turn signals and horn for proper operation.

8. Check for any fuel, oil or hydraulic fluid leaks.

9. Check secondary belt for wear or damage.

10. Service your motorcycle as necessary.

Jiffy Stand Interlock: International Models

Top of page

Some international models are equipped with a jiffy stand interlock feature.

If the rider attempts to start the engine or pushes the starter button while the transmission is in gear and the jiffy stand is down, then the jiffy stand interlock system will not permit the engine to run. The message "SidE StAnd" will scroll across the odometer to indicate this to the rider. Raising the jiffy stand (or putting the transmission in neutral) will permit the engine to run and clear the message.

If the jiffy stand falls out of the fully retracted position while riding at speeds greater than 10 mph 15 km/h , then the jiffy stand interlock system will maintain engine operation and alert the rider about this by illuminating the indicators (flash twice) and scroll the message "SidE StAnd" across the odometer. The message will remain until the system detects the jiffy stand in the fully retracted position again. The rider may continue to operate the vehicle while in this mode.

The rider may clear the text messages at any time by pressing the function switch once while the vehicle is powered up.

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NOTE:

If the operation of raising the jiffy stand and putting the transmission in gear is rapidly executed, the jiffy stand bouncing off the frame could cause the jiffy stand interlock system to activate and stop the engine.

Starting the Engine: Sportster Models

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General

The engine should be allowed to run slowly for 15-30 seconds. This will allow the engine to warm up and let oil reach all surfaces needing lubrication. Failure to comply can result in engine damage. (00563b)

Do not roll the throttle before starting. Rolling the throttle before starting the motorcycle is unnecessary. The engine management system handles starting and running the engine at all temperatures and conditions.

Starting

Shift transmission to neutral before starting engine to prevent accidental movement, which could result in death or serious injury. (00044a)

1. Turn ignition/headlamp key switch to IGNITION position. Do not roll the throttle.

NOTE:

The engine lamp will light for approximately 4 seconds and you will hear the fuel pump purr for approximately 2 seconds as it operates to fill the fuel lines with gasoline.

2. See

Handlebar Controls. Rock the OFF/RUN switch to the RUN position.

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3. Squeeze the clutch lever against the handlebar.

NOTE:

On international models, the jiffy stand must be raised before starting the motorcycle.

4. Press the starter button to start the motorcycle.

5. When the engine has started, you can operate your motorcycle as you normally would after raising the jiffy stand.

NOTE:

If the fuel tank becomes completely dry, it may take a few seconds longer to start the motorcycle after filling the tank. It will not be necessary to take any extraordinary measures before starting the motorcycle.

1. Engine off/run switch

2. Engine start switch

Right Handlebar Controls

Stopping the Engine

Top of page

1. Stop the engine by turning OFF the engine stop switch on right handlebar.

2. Turn OFF the ignition/headlamp key switch. If the engine should be stalled or stopped in any way, turn off the ignition/headlamp key switch at once to prevent battery discharge.

Shifting Gears

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Getting Started

The clutch must be fully disengaged before attempting a gear shift. Failure to fully disengage the clutch can result in equipment damage. (00182a)

From neutral, the shift pattern is first gear down, next four gears up.

NOTE:

Always start engine with transmission in neutral. Always start motorcycle forward motion in first gear.

1. With motorcycle engine running and jiffy stand retracted, pull the clutch hand lever in against handlebar grip to fully disengage clutch.

2. Press the foot shift lever down to end of its travel and release. The transmission is now in first gear.

3. To start forward motion, ease out the clutch lever slowly and at the same time, open throttle gradually.

Upshift (Acceleration)

Refer to Upshift (Acceleration) Gear Speeds. Engage second gear after the motorcycle has reached at the appropriate shifting speed.

Upshift (Acceleration) Gear Speeds

GEAR CHANGE MPH KPH

First to second 15 25

Second to third 25 40

Third to fourth 35 55

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Fourth to fifth 45 70

1. Close the throttle.

2. Disengage the clutch (pull clutch lever in).

3. See Upshift Sequence: Sportster Models. Lift the gear shift lever up to the end of its travel and release.

4. Ease out the clutch lever and gradually open the throttle.

5. Repeat the previous steps to engage third, fourth, and fifth gears.

NOTES:

● Disengage the clutch completely before each gear change.

● Partially close the throttle so the engine will not drag when clutch is again engaged (clutch

lever released).

Upshift Sequence: Sportster Models

Downshift (Deceleration)

Do not downshift at speeds higher than those listed in the Changing Gear Speeds table. Shifting to lower gears when speed is too high can cause the rear wheel to lose traction and lead to loss of vehicle control, which could result in death or serious injury. (00045a)

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Gear shift pattern is first gear down; next four gears up. Refer to Downshift (Deceleration) Gear Speeds for shifting speeds.

Downshift (Deceleration) Gear Speeds

GEAR CHANGE MPH KPH

Fifth to fourth 40 65

Fourth to third 30 50

Third to second 20 30

Second to first 10 15

NOTE:

The shifting points shown in the tables are recommendations. Vehicle owners may determine that their own individual shifting patterns may differ than those stated and are additionally appropriate for individual riding styles.

See

Downshift Sequence: Sportster Models. When engine speed decreases, as in climbing a hill

or running at a reduced speed, shift to the next lower gear while partially closing the throttle so the engine accelerates as soon as the clutch lever is released.

NOTES:

● Disengage the clutch completely before each gear change.

● Partially close the throttle so the engine will not drag when clutch is again engaged (clutch

lever released).

Shift to neutral before stopping engine. Shifting mechanism can be damaged by shifting gears while engine is stopped. (00183a)

The gear shifter mechanism permits shifting the transmission to neutral from either first or second gear.

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Downshift Sequence: Sportster Models

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2008.5 Sportster Models Owner's Manual: Maintenance and Lubrication

Owner's Manuals Print Close Window

Maintenance and Lubrication

Safe Operating Maintenance

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Good maintenance creates a safe motorcycle. A careful check of certain equipment must be made after periods of storage. Also, frequently inspect the motorcycle between the regular service intervals to determine if additional maintenance is necessary.

Check the following items:

1. Tires for correct pressure, abrasions or cuts.

2. Belt and primary chain for proper tension, wear or damage.

3. Brakes, steering and throttle for responsiveness and freedom from binding.

4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.

5. Cables for fraying or crimping and free operation.

6. Engine oil and primary chaincase/transmission fluid levels.

7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.

Break-in Maintenance

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Top of page

NOTE:

The performance of new motorcycle initial service is required to keep your new motorcycle warranty in force and to assure proper emissions system operation.

Refer to

Regular Service Intervals: 2008 Sportster Models. After a new motorcycle has been

ridden its first 1000 miles 1600 kilometers , it should be taken to an authorized Harley-Davidson dealer for initial service operations.

Engine Lubrication

Top of page

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 Recommended Engine Oils. Your authorized dealer has the proper oil to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4.

The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil.

Recommended Engine Oils

H-D TYPE VISCOSITY H-D RATING

LOWEST AMBIENT TEMPERATURE

COLD WEATHER STARTS BELOW 50° F (10° C)

H-D Multigrade

SAE 10W40 HD 360 Below 40° F 4° C Excellent

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H-D Multigrade

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

Checking and Adding Oil: Sportster Models

Top of page

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)

For dipstick location, see

Oil Dipstick Location: Sportster Models (XL Model Shown).

Removing and Replacing Oil Filler Cap

Position motorcycle so that it is leaning on jiffy stand on level ground.

1. 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

Filler Cap/Dipstick Slots: Sportster Models. Note that dipstick has a wide slot and a

narrow slot and can only be inserted in oil tank one way.

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3. Insert dipstick into tank. Turn filler cap 1/4 turn as if screwing filler cap into tank. Press down on cap until flush with oil tank.

Oil Dipstick Location: Sportster Models (XL

Model Shown)

Oil Level Cold Check

1. Position motorcycle so that it is leaning on jiffy stand on level ground.

2. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.

3. Remove oil filler cap again and check oil level on dipstick. See Filler Cap/Dipstick: Sportster Models (typical). Dipstick has two marks. If oil level is at or below lower mark, add only enough oil to bring the level to a point between the two arrows on the dipstick.

Replace filler cap.

NOTE:

Refer to Recommended Engine Oils. Use only recommended oil specified under Engine Lubrication.

Oil Level Hot Check

1. Run engine until engine oil is at normal operating temperature. Turn engine off.

2. Position motorcycle so that it is leaning on jiffy stand on level ground.

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3. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.

4. Remove filler cap again and check warm oil level on dipstick. See Filler Cap/Dipstick: Sportster Models (typical). Dipstick has two marks. If oil level in tank is at or below lower mark, add 1 U.S. qt. 0.946 liter of Harley-Davidson oil to tank.

NOTE:

Refer to Recommended Engine Oils. Use only recommended oil specified under Engine Lubrication.

5. Install filler cap/dipstick back into oil tank.

6. If you added oil in step 4, remove filler cap and verify correct engine oil level in oil tank. Do not fill oil tank to the level above upper mark on dipstick. Replace filler cap.

Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or equipment malfunction. (00189a)

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)

● Check engine oil supply at each complete fuel refill.

● Refer to Regular Service Intervals: 2008 Sportster Models. Oil should be changed at

specified intervals in normal service at warm or moderate temperatures.

● See Winter Lubrication. Oil change intervals should be shorter in cold weather. The same

holds true if the motorcycle is ridden hard under dusty conditions.

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1. Lower mark

2. Upper mark (full)

Filler Cap/Dipstick: Sportster Models

(typical)

1. Wide slot

2. Narrow slot

Filler Cap/Dipstick Slots: Sportster Models

Changing Oil and Filter: Sportster Models

Top of page

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

Refer to

Regular Service Intervals: 2008 Sportster Models. Completely drain oil tank of used

oil at scheduled service intervals. Refill with fresh oil.

NOTES:

● If vehicle is driven extremely hard, used in competition, or driven on dusty roads, change

engine oil at shorter intervals.

● Always replace oil filter when changing engine oil. Genuine Harley-Davidson oil filters are

available in chrome or black finish (Part No. 63796-77A Chrome or Part No. 63805-80A Black).

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Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

Draining Oil Tank

1. Run engine until engine oil has reached normal operating temperature.

2. Remove the oil filler plug/dipstick. Oil will drain more quickly when the filler cap/dipstick is removed from the oil tank.

3. See Oil Tank Drain Hose and Bracket: Sportster Models (XL Model Shown). Place a suitable container directly under the drain hose (1) at the bottom rear of the engine

crankcase. The container must be able to hold approximately 3 U.S. quarts 2.8 liters .

4. Loosen worm drive clamp (2) and pull drain plug (3) from end of drain hose. Completely drain engine oil from oil tank. It is not necessary to drain engine crankcase.

5. Replace drain plug into end of drain hose. Tighten worm clamp.

1. Oil tank drain hose

2. Worm drive clamp

3. Drain plug

Oil Tank Drain Hose and Bracket: Sportster

Models (XL Model Shown)

Removing Oil Filter

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1. Move drain pan beneath front of engine crankcase.

Use Harley-Davidson oil filter wrench for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192b)

2. See

Oil Filter Wrenches and Oil Filter: Sportster Models (XL Model Shown). Remove

oil filter using OIL FILTER WRENCH HD-42311 or HD-44067-A . Turn oil filter counterclockwise to remove from filter mount.

3. Drain oil filter into drain pan. Discard oil filter.

4. Clean any oil spills from crankcase and frame.

NOTE:

Dispose of oil and oil filter in accordance with local regulations.

Oil Filter Wrenches

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1. Crankcase

2. Oil filter

Oil Filter: Sportster Models (XL Model

Shown)

Installing Oil Filter

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)

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 (U.S.) 120 milliliters of fresh, clean engine oil into new oil filter. Allow time for oil to soak into filter element.

2. See

Applying Thin Oil Film. Wipe filter gasket contact surface of oil filter mount with a

clean cloth. Surface should be smooth and free of any debris or old gasket material.

3. Apply a thin film of oil to gasket contact surface on crankcase (3), gasket and new oil filter.

NOTE:

Do not use an oil filter wrench to install new oil filter.

4. Install new oil filter. Screw filter clockwise onto adapter until gasket contacts the filter mount surface. Then hand tighten an additional 1/2 to 3/4-turn to secure the oil filter.

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1. Thin oil film ONLY

2. Oil filter

3. Mounting plate

Applying Thin Oil Film

Refilling Oil Tank

Detach frame clip from frame tube. Loosen worm clamp and remove drain hose from frame clip. Allow a small amount of oil to flow from hose before reconnection. This action removes air from the drain hose and reduces the possibility of oil pump cavitation. (00355a)

1. Refer to

Recommended Engine Oils. Pour 2.8 U.S. quarts 2.65 liters into engine oil tank

minus the 4 fluid ounces 120 milliliters already added in the oil filter. Always use the proper grade of oil for the lowest expected air temperature before the next regularly scheduled oil change.

2. Install filler cap/dipstick in oil tank. Make sure cap is fully seated.

3. Start engine. Verify that oil pressure signal light 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.

Winter Lubrication

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Top of page

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.

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 to thoroughly warm up, this water will accumulate, mix with the engine oil and form a sludge that is harmful to the engine.

Transmission Lubrication: Sportster Models

Top of page

Refer to Regular Service Intervals: 2008 Sportster Models. The transmission should be drained and refilled with fresh lubricant at proper intervals. For best results, drain lubricant while hot.

NOTE:

When checking the transmission lubricant level, motorcycle should be standing STRAIGHT UP, not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize lubricant level in the transmission compartments.

When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

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Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)

Check Lubricant Level

1. Ride motorcycle until engine is warmed up to normal operating temperature.

2. Position motorcycle straight up.

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

3. Remove main fuse. See

Electrical Protection: Sportster Models.

4. See

Mid-Mount Rider Footrest Assembly: XL Models. For XL models equipped with mid-

mount foot controls, remove screws and detach the rider footrest support bracket from the left side of the vehicle.

5. See

Rider Footrest Assembly (Left Side): XR 1200 Model. For XR 1200 model, remove

screws and detach the rider footrest support bracket from the left side of the vehicle. With the shift linkage still attached, lower the footrest assembly to access the clutch inspection cover screws.

6. See

Primary Cover: Sportster Models (XL Model Shown). Remove screws with washers

from clutch inspection cover. Remove clutch inspection cover from primary cover.

NOTE:

The filler access is the clutch inspection cover.

7. See

Chaincase Lubricant Level: Sportster Models. Verify that lubricant level is even with

bottom of clutch diaphragm spring.

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NOTE:

Add only enough of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart) through clutch inspection cover opening until the lubricant reaches the bottom of clutch diaphragm spring.

8. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm).

9. If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 45-50 ft-lbs (61.0-67.8 Nm).

10. Install main fuse.

11. Start engine. Check for any lubricant leaks.

12. Turn engine off.

1. Clutch inspection cover

2. Drain plug

3. Primary chain inspection cover

Primary Cover: Sportster Models (XL Model

Shown)

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1. Clutch diaphragm spring

2. Clutch adjusting screw

3. Quad-ring

4. Primary cover

5. Chaincase lubricant level

Chaincase Lubricant Level: Sportster

Models

Changing Lubricant

1. Ride motorcycle until engine is warmed up to normal operating temperature.

2. When the engine reaches normal operating temperature, turn the engine off and position motorcycle on jiffy stand. This will allow the chaincase lubricant to drain out of transmission.

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

3. Remove main fuse. See

Electrical Protection: Sportster Models.

4. See

Primary Cover: Sportster Models (XL Model Shown). Position a suitable container

under transmission drain plug (2).

5. The drain plug is located under the clutch, on the underside of the chaincase. Remove drain plug and drain lubricant.

6. Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be drained from clutch compartment.

NOTE:

Dispose of lubricant in accordance with local regulations.

Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak. (00200b)

7. Remove foreign material from magnetic drain plug. Install drain plug and tighten to 14-30 ftlbs (19.0-40.7 Nm).

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8. See Mid-Mount Rider Footrest Assembly: XL Models. For XL models equipped with midmount foot controls, remove screws and detach the rider footrest support bracket from the

left side of the vehicle.

9. See

Rider Footrest Assembly (Left Side): XR 1200 Model. For XR 1200 model, remove

10. See

Primary Cover: Sportster Models (XL Model Shown). Remove screws with washers

from clutch inspection cover. Remove clutch inspection cover from primary cover.

NOTE:

The filler access is the clutch inspection cover.

11. Add 32 fluid ounces 946 milliliters of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart) through clutch inspection cover opening.

12. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm).

13. If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 45-50 ft-lbs (61.0-67.8 Nm).

14. Install main fuse.

15. Start engine. Check for any lubricant leaks.

16. Turn engine off.

1. Support bracket

2. Screws (2)

Mid-Mount Rider Footrest Assembly: XL

Models

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1. Rider footrest support bracket

2. Screws (2)

3. Shift linkage

Rider Footrest Assembly (Left Side): XR

1200 Model

Primary Chain Adjustment: Sportster Models

Top of page

General

Refer to Regular Service Intervals: 2008 Sportster Models. Primary (front) chain adjustment should be checked at proper intervals and serviced as necessary. If the chain is allowed to run loose,

it will cause the motorcycle to jerk when running at low speed, and chain and sprockets will wear excessively. If this happens, see a Harley-Davidson dealer or Service Manual for adjustment procedure.

Primary Chain Adjustment: Sportster Models

FREE PLAY INCHES MILLIMETERS

COLD engine 3/8-1/2 9.5-12.7

HOT engine 1/4-3/8 6.3-9.5

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1. Measurement point between sprockets

2. Free play measurement

Primary Chain Vertical Free Play: Sportster

Models

Procedure

The primary chain can be adjusted without removing the primary cover.

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

1. Remove main fuse. See

Electrical Protection: Sportster Models.

2. See

Primary Cover: Sportster Models (XL Model Shown). Remove the two hex socket

screws which secure primary chain inspection cover (3).

3. Rotate sprockets to find tightest point on primary chain.

Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wear. (00202a)

4. See

Primary Chain Adjuster: Sportster Models. Loosen locknut (1).

5. Turn chain adjuster screw (2) clockwise (inward) to reduce free play or counterclockwise (outward) to increase free play. Vertical free play must fall within the limits specified. Refer

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to Primary Chain Adjustment: Sportster Models.

NOTE:

If vertical free play cannot be set within the limits specified, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary.

6. When tension is set correctly, hold chain adjusting screw and tighten locknut to 20-25 ft-lbs (27-34 Nm).

7. Install primary chain inspection cover. Tighten hex socket screws to 40-60 in-lbs (4.5-6.8 Nm).

8. Install main fuse.

1. Locknut

2. Chain adjuster screw

3. Transmission chaincase drain plug

Primary Chain Adjuster: Sportster Models

Rear Drive Belt: Sportster Models

Top of page

General

The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.

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Belt tension is set at the factory and should be checked after the first 1000 miles 1600 kilometers , at scheduled maintenance intervals, and after a hard ride.

Gauging Deflection

Check belt deflection at the loosest spot in the belt with the transmission in neutral and the motorcycle at ambient temperature.

1. With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE HD35381A on the belt.

a. See Gauging Belt Deflection: XR 1200 Model. On XR 1200 model, fit BELT

TENSION GAUGE half-way between the idler wheel and rear sprocket.

b. See

Gauging Belt Deflection: Sportster XL Models. On all other models, position

the gauge half-way between the transmission and rear wheel sprockets.

2. With the BELT TENSION GAUGE set to 0 lbs. 0 kg , note the current belt position.

a. See

Belt Deflection: XR 1200 Model. On XR 1200 model, note the belt position

according to the graduations on the front of the debris deflector.

b. See

Belt Deflection Window (typical). On all other models, note the belt position

according to the graduations on the belt deflection window located on the rear drive belt guard.

3. Using the BELT TENSION GAUGE, apply 10 lbs. 4.5 kg of force to the bottom belt. Count the number of graduations between the original belt position and after applying the force. Multiply this number by 1/8 in. 3.2 mm to determine the deflection.

4. Refer to

Belt Deflection: Sportster Models for the recommended deflection. If belt

tension adjustment is necessary, see a Harley-Davidson dealer or follow the belt deflection adjustment procedure in the Service Manual.

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

NOTE:

When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run true within brake caliper.

Belt Deflection: Sportster Models

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MODELS INCHES MILLIMETERS

XL 883C, XL 883L, XL 1200C, XL 1200L, XL 1200N

1/4-5/16 6.4-7.9

XL 883, XL 883R, XL 1200R 9/16-5/8 14.3-15.9

XR 1200 1/4-3/8 6.4-9.5

1. Rear drive belt

2. Deflection graduations 1/8 in. (3.2 mm) apart

Belt Deflection Window (typical)

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1. Rear drive belt

2. Deflection graduations 1/8 in. (3.2 mm) apart

Belt Deflection: XR 1200 Model

1. Transmission sprocket

2. Rear wheel sprocket

3. Force of 10 lbs (4.5 kg)

4. Deflection (refer to table)

Gauging Belt Deflection: Sportster XL

Models

1. Transmission sprocket

2. Rear wheel sprocket

3. Force of 10 lbs (4.5 kg)

4. Deflection (refer to table)

5. Idler wheel

Gauging Belt Deflection: XR 1200 Model

Chassis Lubrication

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Top of page

Refer to Regular Service Intervals: 2008 Sportster Models for all maintenance schedules.

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

1. Use recommended special purpose grease for steering head bearings. Use a multipurpose chassis grease for other applications.

2. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite at proper intervals.

3. Lubricate throttle control cables and clutch control cable at proper intervals.

4. Lubricate front brake hand lever and clutch control hand lever only if necessary.

5. Inspect rear fork pivot shaft bearings.

6. Pack the steering head bearings with fresh grease at proper intervals.

7. Lubricate the jiffy stand mechanism with LOCTITE AEROSOL ANTI-SEIZE at proper intervals.

NOTE:

For model specific information regarding the chassis lubrication, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Oil Applications

Top of page

Refer to Regular Service Intervals: 2008 Sportster Models for all control connections and parts. Vehicle should be oiled at regular intervals, particularly after washing motorcycle or driving in wet

weather.

Front Fork Oil

Top of page

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Refer to Regular Service Intervals: 2008 Sportster Models. Have a Harley-Davidson dealer drain the front fork oil and refill at proper intervals. If fork does not appear to be working properly

or an appreciable amount of oil leakage should develop, see a Harley-Davidson dealer. If there is insufficient oil in either side of fork, the rebound action will be incorrect.

Clutch

Top of page

The clutch control cable must be oiled and adjusted periodically to compensate for lining wear. See Service Interval Table. Failure to oil and adjust the clutch control cable can result in equipment damage. (00203a)

The need for attention to clutch and controls will be indicated by the clutch slipping under load or dragging when released. In this situation, check the control cable adjustment first. See a HarleyDavidson dealer for proper service.

Hydraulic Lifters

Top of page

The hydraulic lifters are self-adjusting. They automatically adjust length to compensate for engine expansion and valve mechanism wear. This keeps the valve mechanism free of lash when the engine is running.

When starting an engine which has been turned off even for a few minutes, the valve mechanism may be slightly noisy until the hydraulic units completely refill with oil. If at any time the valve mechanism becomes abnormally noisy, other than for a short period immediately after engine is started, it is an indication that one or more of the hydraulic units may not be functioning properly.

Always check the oil supply in the oil tank first since normal circulation of oil through the engine is necessary for proper operation of the hydraulic units.

If there is oil in the tank, the units may not be functioning properly because of dirt in the oil supply passages leading to the lifter units. See a Harley-Davidson dealer for service.

Front Fork Bearings

Top of page

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HARLEY-DAVIDSON XL883N User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual