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Harley Davidson XL1200C Sportster Custom Motorcycle 2004-2006 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Model Variant: Sportster Custom Year: 2004-2006 Codes Engine Code Family: Evolution (Big Twin) Chassis Code Family: XL (Sportster) 👋 Introduction...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL1200C Sportster Custom
Model Variant:
Sportster Custom
Year:
2004-2006
Codes
Engine Code Family:
Evolution (Big Twin)
Chassis Code Family:
XL (Sportster)
👋 Introduction
Market Position
Segment:
Cruiser, Custom Motorcycle
Target Audience:
Riders seeking classic styling, customization potential, and V-twin performance
Competitive Analysis
Key Competitors:
Indian Scout, Triumph Bonneville, Yamaha Bolt, various custom V-twin builders
Key Features Vehicle
Engine Type:
Air-cooled, Evolution V-twin
Styling:
Classic cruiser lines, ample chrome, customizable elements
Ride Quality:
Torquey engine, comfortable riding position for cruising
Key Features Manual
Value Proposition:
Comprehensive factory documentation for maintaining and repairing the specific model years
Licensing:
No expiry dates, unrestricted access
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Assembly, Disassembly
Page Count
Estimated Page Count:
600+
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full rebuild procedures, component testing, torque specifications, timing, lubrication system
Fuel System:
Carburetor (CV) diagnosis and tuning, fuel pump, fuel lines, fuel tank maintenance
Ignition System:
Spark plugs, ignition coils, electronic control module (ECM) diagnostics, timing advance
Transmission Drivetrain:
Clutch operation, gearshift mechanism, primary drive, final drive belt inspection and adjustment
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter system, fuses, relays
Brakes System:
Front and rear brake caliper service, master cylinder, brake fluid flushing and bleeding, rotor inspection
Suspension System:
Front fork disassembly, seal replacement, fluid levels, rear shock absorber service and adjustment
Wheel Tire System:
Wheel bearing inspection, tire pressure, wheel balancing, spoke tension (if applicable)
Frame Bodywork:
Frame inspection, body panel removal and installation, seat mounting, fender service
Controls:
Handlebar, grips, levers, cables (throttle, clutch) adjustment and replacement
Exhaust System:
Exhaust pipe and muffler inspection, mounting, gasket replacement
Procedures Included
Basic Maintenance:
Oil changes, filter replacement, chain/belt adjustment, lubrication points, tire pressure checks
Intermediate Repairs:
Brake pad replacement, clutch cable adjustment, fork seal replacement, spark plug replacement
Advanced Repairs:
Engine top-end rebuild, transmission disassembly, carburetor overhaul, electrical system troubleshooting
Troubleshooting:
Diagnostic charts for common symptoms (e.g., starting issues, poor performance, electrical faults)
Specifications:
Detailed torque values for all fasteners, fluid capacities, electrical resistance values, engine clearances
Wiring Diagrams:
Comprehensive, color-coded wiring schematics for all electrical components
Technical Depth
Depth:
Comprehensive factory-level detail suitable for professional mechanics and experienced DIY enthusiasts
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable text within the PDF document
Print Quality
Print Readability:
High-resolution, printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, Evolution
Displacement:
1200 cc (73.2 cu in)
Bore X Stroke:
3.496 in x 3.811 in (88.8 mm x 96.8 mm)
Compression Ratio:
9.0:1
Valve Train:
Pushrod-actuated, overhead valves (OHV), 2 valves per cylinder
Cooling System:
Air-cooled
Performance
Horsepower Estimated:
Approximately 65-70 HP (specific factory figures may vary)
Torque Estimated:
Approximately 70-75 lb-ft (specific factory figures may vary)
Fuel System
Fuel Delivery:
Carburetor (Keihin CV 40 mm)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication
Oil Type:
Harley-Davidson 20W50 Motorcycle Oil or equivalent (refer to manual for specific H-D P/N)
Oil Capacity:
3.0 US qt (2.8 L) with filter change (refer to manual for precise capacity)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 34/46 ratio
Final Drive:
Belt drive, 32/65 ratio
Features
Clutch Type:
Wet, multi-plate
Transmission Oil Type:
Harley-Davidson Formula Plus or equivalent (refer to manual for specific H-D P/N)
Transmission Oil Capacity:
2.7 US qt (2.5 L) (refer to manual for precise capacity)
📐 Dimensions
Exterior
Length:
Approximately 90.4 inches (2296 mm)
Width:
Approximately 37.6 inches (955 mm)
Height:
Approximately 47.6 inches (1209 mm)
Weights
Dry Weight:
Approximately 562 lbs (255 kg)
Gross Vehicle Weight Rating:
Not specified, refer to VIN plate/manual
Wheels Tires
Front Tire Size:
100/90-19 57H
Rear Tire Size:
150/80B16 77H
Wheel Type:
Chrome laced or solid cast aluminum (depending on specific trim/options)
Wheelbase:
Approximately 60.0 inches (1524 mm)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle) - Safety depends on rider skill and adherence to maintenance
Active Features
Brakes:
Dual-action front and rear disc brakes
Lighting:
Halogen headlamp, LED tail/brake lamp, incandescent turn signals
Passive Features
Frame Construction:
Steel, rigid backbone frame
Ergonomics:
Forward-mounted foot controls, swept-back handlebars for cruising comfort and control
💡 Technology Features
Infotainment
Audio System:
Base models typically do not have integrated audio systems; aftermarket options are common.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature for these model years, not standard on all variants.
Connectivity
Vehicle Data:
Basic analog speedometer, tachometer, and indicator lights. No advanced digital displays or connectivity features as standard.
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Engine Oil Change:
Every 5,000 miles (8,000 km) or 12 months
Subsequent Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months
Final Drive Belt Inspection:
Every 5,000 miles (8,000 km) or 12 months, check tension and condition
Brake Fluid Flush:
Every 24 months, regardless of mileage
Fluid Specifications
Engine Oil:
Harley-Davidson SYN3 Synthetic or H-D 20W50 Motorcycle Oil (P/N 62600001 or equivalent)
Transmission Oil:
Harley-Davidson Formula Plus (P/N 99873-97 or equivalent)
Primary Chain Case Oil:
Harley-Davidson Primary Chaincase Lubricant (P/N 99860-97 or equivalent)
Brake Fluid:
DOT 4
Fork Oil:
Harley-Davidson Type E Fork Oil (7.5W) or equivalent (refer to manual for specific type and quantity)
Known Issues
Cam Chain Tensioner:
Early models (pre-2007) had hydraulic tensioners that could wear out; the manual will detail inspection and replacement procedures (upgrade kits often available).
Regulator Rectifier:
Can be a failure point on some Harley models; manual covers testing and replacement.
Carburetor Tuning:
CV carburetor can require periodic adjustment for optimal performance, especially with exhaust/intake modifications.
Belt Drive Tension:
Improper tension can lead to premature wear on the belt and pulleys; manual provides correct adjustment specs.
📚 Vehicle History
Brand Heritage
Brand Origin:
Founded in Milwaukee, Wisconsin, USA in 1903
Motorcycle Type:
Pioneer in American motorcycle manufacturing, known for V-twin engines and cruiser styling
Model Evolution
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running and most iconic model families.
Xl1200C Development:
The XL1200C (Custom) variant evolved from earlier Sportster models, emphasizing a more 'custom' look with features like a larger front wheel, teardrop fuel tank, and often higher-spec finishes.
Production
Manufacturing Location:
USA
Model Years Covered:
Specifically for 2004, 2005, and 2006 model years, which are part of the rubber-mount Sportster generation.
🏆 Awards & Recognition
Recognitions
Model Recognition:
Consistently ranked as a popular and reliable model within the Harley-Davidson lineup and its segment.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to its classic appeal and customizability.
Certifications
Manual Certification:
Factory original service documentation.