Target Audience:
Harley-Davidson Sportster owners, independent mechanics, enthusiasts seeking detailed service information
Value Proposition:
Provides factory-level repair and maintenance guidance, crucial for proper upkeep and longevity of the Sportster platform
Manual Strength:
Authoritative content directly from Harley-Davidson's technical documentation
Diagnostic Focus:
Excellent troubleshooting section to identify and resolve common and complex issues
Engine Internal:
Top End (cylinder heads, valves, pistons), Lower End (crankshaft, connecting rods, bearings)
Drivetrain:
Clutch & Primary Drive, Transmission, Shift Mechanism
Fuel And Exhaust:
Fuel System (carburetor/fuel injection), Exhaust System
Electrical And Ignition:
Ignition System, Charging System, Starting System, Lighting, Instrumentation
Chassis And Suspension:
Frame, Front Suspension (forks), Rear Suspension (shocks), Wheels, Tires, Brakes
Bodywork And Trim:
Body panels, fenders, fuel tank, seat, handlebars
Routine Maintenance:
Oil changes, filter replacement, spark plug checks, chain adjustment, brake checks, tire pressure
Troubleshooting:
Diagnostic charts, symptom-based problem solving, common issue identification
Repair And Rebuild:
Engine internal component replacement, transmission overhaul, clutch service, brake caliper service
Tune Up:
Carburetor adjustment, ignition timing checks, idle speed settings
Lubrication:
Lubrication points, fluid type specifications, capacities
Depth Of Coverage:
Detailed step-by-step instructions, torque specifications, special tool requirements, wiring diagrams
Diagnostic Capabilities:
Advanced troubleshooting for electrical and mechanical systems
Rebuild Instructions:
Complete engine and transmission rebuild procedures
Digital Format:
N/A (assuming printed book)
Paper Quality:
Durable, heavy-stock paper designed for workshop use
Print Clarity:
High-resolution diagrams and text for easy readability
Binding:
Stitched and/or glued binding for durability
Cover Type:
Sturdy cardstock or laminated cover for protection
Engine Family:
Evolution (Evo) V-Twin Engine
Engine Configuration:
Air-cooled, 45-degree V-twin
Engine Displacement Options:
883cc (53.9 cu in) and 1200cc (73.2 cu in)
Engine Bore Stroke 883:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Engine Bore Stroke 1200:
88.9 mm x 96.8 mm (3.50 in x 3.81 in)
Compression Ratio 883:
Approximately 9.0:1
Compression Ratio 1200:
Approximately 9.7:1 (may vary by sub-model)
Fuel Delivery System:
Carburetor (Keihin CV40 or similar) or Electronic Fuel Injection (EFI) depending on specific model variant
Fuel Type:
Unleaded gasoline, minimum octane rating 91 (AKI)
Valve Actuation:
Overhead valves (OHV), pushrod actuated
Valve Adjustment:
Hydraulic lifters, typically requires periodic inspection/adjustment of pushrods
Transmission Type:
5-speed Constant Mesh Manual
Transmission Options:
N/A (5-speed was standard for this generation)
Primary Drive:
Enclosed, wet multi-plate clutch, chain drive to transmission
Transmission Fluid Type:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent specification)
Transmission Fluid Capacity:
Approximately 24 US fl oz (0.71 L)
Wheelbase:
Approx. 60 inches (1524 mm) (varies slightly by model)
Seat Height:
Approx. 28 inches (711 mm) (unladen, varies by model)
Dry Weight:
Approx. 560-580 lbs (254-263 kg) (varies by model)
Gross Vehicle Weight Rating:
Approx. 960-1000 lbs (435-454 kg)
Safety Certification:
Meets relevant DOT and EPA standards for motorcycles
Braking System:
Dual front disc brakes (caliper type may vary), single rear disc brake
Lighting:
Halogen headlamp, LED tail/brake lights, incandescent turn signals
Frame Construction:
Steel frame and swingarm designed for stability
Infotainment System:
Basic instrumentation: speedometer, tachometer (optional), odometer, trip meter, neutral indicator, oil pressure light, engine diagnostic indicator
Driver Assistance Features:
N/A (standard features for this era of Sportster)
Oil Change Interval:
Every 5,000 miles or 12 months, whichever comes first
Primary Fluid Change Interval:
Every 10,000 miles or 24 months
Transmission Fluid Change Interval:
Every 10,000 miles or 24 months
Spark Plug Replacement Interval:
Every 10,000 miles
Engine Oil Type:
Harley-Davidson 20W-50 Syn3 or equivalent motorcycle-specific synthetic oil
Engine Oil Capacity:
Approx. 3 US quarts (2.8 L) with filter change
Common Wear Items:
Clutch friction plates, brake pads, wheel bearings, fork seals
Engine Considerations:
Potential for oil leaks from primary or engine cases, carburetor jetting for altitude/performance modifications
Electrical Considerations:
Voltage regulator or stator failure can occur over time, check battery connections
Heritage:
Harley-Davidson, established in 1903, renowned for its V-twin motorcycles and iconic American lifestyle
Sportster Lineage:
The Sportster line dates back to 1957, evolving through numerous iterations, with this 2004-2006 generation featuring a rubber-mounted Evolution engine for improved rider comfort.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri plants)
