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Harley Davidson XL1200L Sportster Low 2004-2006 Manual

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This manual provides comprehensive information for the XL1200L Sportster Low, covering production years 2004 through 2006. Known for its iconic Evolution V-Twin engine and accessible 'Low' riding profile, the XL1200L...
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Taper: Motorcycle
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UGS: 64569
Harley Davidson XL1200L Sportster Low 2004-2006 ManualHarley Davidson XL1200L Sportster Low 2004-2006 ManualHarley Davidson XL1200L Sportster Low 2004-2006 Manual
This manual provides comprehensive information for the XL1200L Sportster Low, covering production years 2004 through 2006. Known for its iconic Evolution V-Twin engine and accessible 'Low' riding profile, the XL1200L is designed for riders seeking classic American cruiser performance and style. This workshop repair service manual delves into the engineering quality and reliability that define the brand, offering insights into the model's chassis and engine specifications, including its air-cooled, 45-degree V-twin configuration. This factory workshop repair service manual is an indispensable resource for owners, mechanics, and technicians. It offers detailed, step-by-step procedures for maintenance, diagnosis, and repair of all systems, including the engine, fuel system, chassis, brakes, and electrical components. With hundreds of pages of diagrams and information, this manual ensures accurate and complete guidance, enabling effective troubleshooting and proper upkeep of your XL1200L Sportster Low.
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL1200L Sportster Low
Year:
2004-2006
Product Type:
Workshop Repair Service Manual
Product Format:
PDF Download
Codes
Engine Code:
Evolution V-Twin
Chassis Code:
XL
👋 Introduction
Market Position
Target Audience:
Harley-Davidson XL1200L Sportster Low owners, mechanics, enthusiasts
Value Proposition:
Enables DIY repairs, saving significant costs; provides professional-level service information
Competitive Analysis
Manual Type Comparison:
Equivalent to factory manuals, often superior to aftermarket options in detail and accuracy
Key Features
Key Selling Points:
Completeness, accuracy, ease of use, instant access, cost savings
Information Layout:
Numbered instructions, bold figure numbers, detailed illustrations, enlarged insets
📋 Manual Details
Coverage Areas
Coverage:
All Models/Engines/Trim/Transmissions Types for XL1200L Sportster Low 2004-2006
Page Count
Estimated Pages:
Hundreds of pages (as stated in product description)
Manual Type
Type:
Factory Workshop Repair Service Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
Printability:
Full Printable
Zoom Capability:
Zoom IN/OUT
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
General Information:
Included
Maintenance:
Included
Chassis:
Included
Fuel System:
Included
Cooling System:
Included
Engine:
Included
Clutch:
Included
Engine Lubrication System:
Included
Engine Removal Installation:
Included
Drive System:
Included
Transmission:
Included
Wheels Tires:
Included
Final Drive:
Included
Brakes:
Included
Suspension:
Included
Steering:
Included
Frame:
Included
Electrical System:
Included
Wiring Diagrams:
Included
Procedures Included
Diagnostic Procedures:
Comprehensive
Repair Procedures:
Detailed, step-by-step
Maintenance Procedures:
Included
Disassembly Assembly:
Included
Cleaning Reinstalling:
Included
Troubleshooting:
Included, combined with electrical service
Tool Requirements:
Specified with procedures
Technical Depth
Depth:
Professional, as used by local service/repair shops
Accuracy:
Original, accurate, and complete
Content Quality:
Hundreds of pages of diagrams and detailed information
Information Access:
Comprehensive diagnostic, repair, and maintenance information
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High quality, printable
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Evolution V-Twin
Displacement:
1200cc (approx. 73.2 cubic inches)
Configuration:
Air-cooled, 45-degree V-twin
Performance
Horsepower Estimate:
Typically in the 60-70 HP range (specifics in manual)
Torque Estimate:
Typically in the 70-80 lb-ft range (specifics in manual)
Fuel System
Fuel Delivery:
Fuel Injection (EFI) for models in this range, potentially Carbureted options depending on exact sub-model or market
Fuel Type:
Unleaded gasoline (specific octane rating in manual)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Optional
Optional Transmissions:
N/A (typically standard 5-speed for XL1200L)
Features
Drive Type:
Belt Drive (final drive)
📐 Dimensions
Exterior
Seat Height Laden:
Approx. 25.3 inches (643 mm) - designed for 'Low' profile
Weights
Dry Weight:
Approx. 563 lbs (255 kg) - specific variations may exist
Gross Vehicle Weight Rating:
Specific GVWR would be detailed in the manual
🛡️ Safety Features
Ratings
Safety Standards:
Meets relevant US DOT and EPA standards for motorcycles of the era
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Lighting:
Halogen headlight, taillight, stop light, turn signals
💡 Technology Features
Infotainment
Audio System:
Base models typically do not include advanced infotainment; aftermarket options are common. Manual will detail any factory-fitted features for specific trims.
Driver Assistance
Rider Aids:
Limited rider aids in this era; focus is on mechanical and electrical systems. Manual covers ABS if equipped (less common on early XL1200L).
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or smartphone integration from the factory. Manual focuses on core vehicle functions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically 5,000 miles or annually)
Primary Chain Tensioner:
Check and adjust as needed, specific intervals in manual
Spark Plugs:
Replace based on mileage or inspection (manual will specify)
Fluid Specifications
Engine Oil Type:
Harley-Davidson recommended V-Twin specific oil (e.g., SAE 20W50 or similar, consult manual for exact spec)
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Lubricant or equivalent (manual will specify)
Transmission Oil:
Harley-Davidson transmission lubricant or equivalent (manual will specify)
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid (verify exact specification in manual)
Known Issues
Primary Chain Tensioner Wear:
Hydraulic tensioner in the primary drive can wear out, leading to noise and potential damage. Manual will detail inspection and replacement.
Carburetor Adjustment Idle Mixture:
For carbureted models, proper idle mixture adjustment is crucial for smooth running. Manual provides precise procedures.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues. Manual's wiring diagrams are key.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Model Evolution
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving significantly over the decades.
Xl1200L Introduction:
The XL1200L 'Low' variant was introduced to cater to riders seeking a more accessible seat height and relaxed riding position.
Production
Production Period:
Covered years: 2004, 2005, 2006
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