Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Segment:
Cruiser/Custom Motorcycle
Target Audience:
Owners and mechanics performing maintenance and repairs on Harley-Davidson XL Sportster models.
Competitors:
Manuals for other American V-twin motorcycles, as well as Japanese and European cruisers.
Manual Strength:
Comprehensive coverage, detailed diagrams, and step-by-step procedures essential for maintaining and repairing the Sportster platform.
Engine:
Engine overhaul, top-end rebuild, lubrication system, cooling system (air-cooled specific details), fuel injection system (EFI), ignition system, starting system, charging system.
Transmission:
Clutch service, transmission overhaul, gear inspection, shift linkage adjustment, primary drive maintenance.
Electrical:
Wiring diagrams, component testing, lighting system, instrumentation, battery management, security system, handlebar controls, ECU diagnostics.
Brakes:
Front and rear brake system overhaul, hydraulic component replacement, bleeding procedures, brake pad and rotor specifications.
Suspension:
Front fork service (telescopic forks), rear shock absorber replacement and adjustment, swingarm service, wheel bearing maintenance.
Frame And Body:
Frame inspection, body panel removal/installation, fuel tank service, seat assembly, fenders, exhaust system.
Wheel And Tire:
Wheel and tire inspection, spoke tension, balancing, valve stem replacement.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter service, chain adjustment (if applicable to specific sub-models), brake fluid flush, battery maintenance.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common electrical and mechanical faults, diagnostic trouble codes (DTCs) and their meanings.
Repair And Rebuild:
Detailed instructions for engine component disassembly, inspection, and reassembly; transmission rebuild; suspension fork rebuild; brake caliper overhaul.
Technical Specifications:
Torque specifications for all fasteners, engine timing procedures, valve clearance adjustment (if applicable to model variants), fluid capacities, electrical resistance values.
Depth:
Detailed enough for professional mechanics and experienced DIY enthusiasts. Covers complete engine rebuilds, transmission overhauls, and complex electrical diagnostics.
Engine Family:
Evolution (Evo) V-Twin
Displacement Options:
Primarily 883cc (57.5 cu in) and 1200cc (73.2 cu in) Evolution engines for this period.
Cooling System:
Air-cooled
Bore X Stroke 883:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore X Stroke 1200:
88.9 mm x 96.8 mm (3.50 in x 3.81 in)
Horsepower 883 Approx:
50-55 HP
Torque 883 Approx:
55-60 lb-ft
Horsepower 1200 Approx:
65-70 HP
Torque 1200 Approx:
70-75 lb-ft
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) for most models in this range.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2 (AKI) recommended.
Cylinder Arrangement:
45-degree V-twin
Type:
5-speed constant mesh sequential manual transmission
Availability:
N/A for this generation of Sportster.
Primary Drive:
Enclosed, wet, multi-plate clutch. Primary drive via duplex chain.
Primary Chain Case Oil:
Harley-Davidson Formula+ (or equivalent API GL-4, SAE 50, non-synthetic motor oil for primary) - Capacity approx. 2.4 quarts (2.3L).
Transmission Oil:
Harley-Davidson transmission lubricant or equivalent API GL-5, SAE 80W-90 gear oil - Capacity approx. 1 quart (0.95L).
Safety Certification:
DOT, EPA, CARB compliant.
Braking System:
Dual-piston front caliper, single-piston rear caliper. Optional ABS available on select models/trims.
Lighting:
Halogen headlamp, LED tail lamp, incandescent turn signals.
Security:
Factory-installed H-D Smart Security System (key fob) on many models.
Instrumentation:
Analog speedometer with integrated tachometer (on some models), odometer, trip meter, fuel gauge (in tank or LCD), indicator lights.
ABS:
Anti-lock Braking System (ABS) available as an option on certain trims and years within this range.
Diagnostic Port:
On-board diagnostics (OBD-II compliant for EFI systems) with a diagnostic connector for fault code retrieval and system analysis.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Belt Check Tension:
Check belt tension every 5,000 miles (8,000 km).
Engine Oil:
Harley-Davidson SYN3 (SAE 20W-50 Full Synthetic) or equivalent air-cooled V-twin specific motorcycle oil meeting Harley-Davidson specifications (e.g., API CI-4 or higher).
Engine Oil Capacity:
Approximately 3 quarts (2.8L) for 883cc, 3.5 quarts (3.3L) for 1200cc (check manual for exact capacity).
Brake Fluid:
DOT 4 recommended for hydraulic brake systems.
Clutch Actuation:
Some models may experience stiffer clutch pull, adjustable via linkage or aftermarket components. The manual will detail proper adjustment procedures.
Rear Shock ABSorbers:
Stock shocks can be considered basic; manual provides adjustment details and replacement guidance.
Idle Control:
EFI models may require idle speed adjustment through electronic diagnostics or specific procedures outlined in the manual.
Generation Significance:
This period represents a significant update for the Sportster, notably the introduction of Electronic Fuel Injection (EFI) and potential updates to suspension and chassis components.
Engine Development:
The Evolution engine, introduced in 1984, saw continuous refinement, with this generation benefiting from significant electronic integration.
Manufacturing Location:
York, Pennsylvania, USA
