🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Model Line:

XL Series

Covered Years:

2004, 2005, 2006

Product Identifier:

HDS0406WSRM

👋 Introduction

Positioning:

Essential technical resource for owners and independent mechanics of Harley-Davidson Sportster models from the mid-2000s

Alternatives:

Factory Service Manuals (FSM), Haynes, Clymer manuals

Advantage:

Directly from factory-level data, offering the most accurate and comprehensive information for this specific generation

Value Proposition:

Empowers owners to perform detailed maintenance and repairs, saving on dealership costs and ensuring proper upkeep

User Base:

DIY mechanics, custom builders, Sportster enthusiasts

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Scope:

Comprehensive maintenance, troubleshooting, and repair

Estimated Pages:

Approximately 500-700 (typical for this era's full service manuals)

Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Evolution V-Twin (88ci/1450cc, 96ci/1584cc - depending on specific model variants within the range)

Fuel System:

Carbureted (Keihin CV type) and Electronic Fuel Injection (EFI) systems

Ignition System:

Electronic ignition, spark plugs, coils, ignition modules

Transmission:

5-speed constant mesh transmission, clutch system, primary drive

Drivetrain:

Belt drive system, final drive belt maintenance

Chassis:

Frame, swingarm, suspension (front forks, rear shocks)

Brakes:

Front and rear hydraulic brake systems, calipers, master cylinders, lines, pads, rotors

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, switches, gauges

Bodywork:

Fuel tank, fenders, seat, handlebars, controls, minor body components

Wheels And Tires:

Wheel bearing maintenance, tire inspection and replacement, wheel specifications

Lubrication:

Engine oil, transmission oil, primary chaincase oil specifications and change procedures

Routine Maintenance:

Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), brake checks

Engine Overhaul:

Top-end rebuild, piston and cylinder replacement, valve adjustments, gasket replacements

Transmission Repair:

Clutch adjustments, transmission disassembly and reassembly, gear inspection

Electrical Diagnostics:

Troubleshooting electrical faults, testing components, wiring harness repair

Brake Service:

Brake bleeding, pad replacement, caliper service, master cylinder overhaul

Suspension Service:

Fork seal replacement, fork oil changes, rear shock absorber maintenance

Fuel System Service:

Carburetor tuning and rebuilding, fuel injector cleaning and testing (for EFI models)

Troubleshooting Guides:

Diagnostic charts for common symptoms and potential causes

Technical Specifications:

Torque values, clearances, fluid capacities, electrical resistance values

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagnostic Level:

Advanced diagnostics, including electrical system troubleshooting

Rebuild Instructions:

Detailed, step-by-step instructions for major component rebuilds

📊 Manual Specifications

Format Details:

Digital PDF, typically searchable and printable

Quality:

High-resolution scans of original factory manual pages

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

Text Search:

Typically searchable PDF content

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Evolution (V-Twin)

Displacement:

88 cubic inches (1450cc) and potentially 96 cubic inches (1584cc) for later 2006 models (confirm specific sub-model)

Configuration:

Air-cooled, 45-degree V-twin, overhead valves (OHV)

Bore X Stroke:

88ci: 3.50 in x 4.47 in (88.9 mm x 113.5 mm); 96ci: 3.75 in x 4.38 in (95.25 mm x 111.25 mm) - Check specific model for exact dimensions

Horsepower:

Approximately 65-75 HP (Varies by year and specific model, e.g., XL1200C, XL883R)

Torque:

Approximately 70-85 ft-lbs (Varies by year and specific model)

Carbureted Model:

Keihin CV (Constant Velocity) 40mm carburetor

Efi Model:

Electronic Fuel Injection (EFI) with Delphi/H-D ECU

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/95 ROZ

Oil Type:

Harley-Davidson recommends specific motorcycle-grade synthetic or semi-synthetic oils, typically SAE 20W-50

Oil Capacity:

Approximately 3 US quarts (2.8 liters) for engine and primary drive combined, check manual for exact figure

Method:

Air-cooled

Actuation:

Pushrod-actuated, overhead valves

🔧 Transmission

Type:

5-speed Constant Mesh

Gear Ratios:

Specific ratios are detailed in the manual, but generally provide a good balance for cruising and acceleration

Optional Types:

N/A for this model year range (5-speed was standard)

Primary Drive:

HyVo chain drive in a separate oil bath (primary chaincase)

Final Drive:

Belt drive (45-tooth rear pulley, 32-tooth front sprocket)

Transmission Oil:

Harley-Davidson Formula + transmission & primary chaincase lubricant or equivalent SAE 50 motorcycle gear oil

Transmission Capacity:

Approximately 1 US quart (0.95 liters) for the primary chaincase, check manual

📐 Dimensions

Wheelbase:

Approx. 59.6 inches (1514 mm) for XL1200C, 57.1 inches (1450 mm) for XL883C

Length:

Varies by model (e.g., XL1200C approx. 89.7 inches / 2278 mm)

Dry Weight:

Approx. 550-570 lbs (250-260 kg) depending on model

Gvwr:

Typically around 950-1000 lbs (430-455 kg)

Cargo Capacity:

Minimal, primarily rider and small accessories. Optional saddlebags available.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subjected to the same crash testing protocols as automobiles)

Braking System:

Hydraulic disc brakes, front and rear. ABS was not standard on most Sportsters in this era, but check specific sub-model.

Lighting:

Halogen headlight, LED taillight (on some models), turn signals

Frame Construction:

Steel tube frame, providing structural integrity

Rider Controls:

Handlebar-mounted controls, foot controls, rider seating position

💡 Technology Features

Infotainment System:

Minimal; typically features analog speedometer, tachometer (optional), odometer, trip meter, and indicator lights. No integrated audio or navigation.

Driver Assistance Features:

None. Primarily rider-focused with basic instrumentation.

ECU:

Electronic Control Unit (ECU) for EFI models managing fuel injection and ignition timing.

🔧 Maintenance

First Service:

Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first

Subsequent Services:

Every 5,000 miles (8,000 km) or 12 months for most checks; specific intervals for oil, transmission fluid, and other components detailed in the manual.

Engine Oil Specification:

H-D SAE 20W-50 SYN3 or equivalent air-cooled V-twin motorcycle oil

Primary Chaincase Fluid:

H-D Formula + or equivalent SAE 50 motorcycle gear oil

Brake Fluid:

DOT 4 hydraulic brake fluid

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, drive belt

Potential Problems:

Carburetor tuning (CV type), charging system output (stator/regulator), fuel tank expansion (rare on these models)

Oil Filter Example:

Harley-Davidson P/N 63796-77 (or equivalent aftermarket, consult manual)

Spark Plug Example:

Harley-Davidson P/N 31606-01 (or equivalent, e.g., NGK DPR7EA-9)

📚 Vehicle History

Brand Legacy:

Harley-Davidson, established in 1903, renowned for its cruiser and touring motorcycles

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, known for its sporty character and accessible performance.

2004 Update:

The 2004 model year marked a significant chassis redesign, adopting the new frame that would persist for several years, improving handling and rider ergonomics.

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin facilities)

🏆 Awards & Recognition

Model Reputation:

The Sportster line consistently receives acclaim for its customization potential, classic styling, and accessible entry into Harley-Davidson ownership. Specific awards for these individual model years are less common than general acclaim for the platform.