Product Type:
Service Repair Manual
Covered Model Years:
2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson XL Sportster owners, independent motorcycle mechanics, and enthusiasts performing their own maintenance and repairs.
Key Competitors:
Indian Scout, Triumph Bonneville, Kawasaki Vulcan, Honda Shadow.
Illustration Quality:
Illustrated with clear step-by-step instructions and detailed diagrams.
Accessibility:
Digital download provides immediate access to repair information.
Completeness:
A comprehensive guide for maintaining and repairing the specific model years.
Primary Coverage:
Mechanical and electrical service, repair, and maintenance of Harley-Davidson XL Sportster motorcycles.
Engine Coverage:
Engine assembly, disassembly, tuning, troubleshooting, and component replacement for Evolution V-Twin engines.
Transmission Coverage:
Clutch, gearbox, and final drive maintenance and repair.
Electrical Coverage:
Wiring diagrams, ignition system, lighting, instrumentation, and accessory installation.
Chassis Coverage:
Frame, suspension (forks, shocks), wheels, tires, brakes (front and rear), steering, and fuel system.
Estimated Pages:
Approximately 500-800 pages (digital format often contains more comprehensive data).
Type:
Service/Repair Manual
Primary Language:
English
Download Format:
Downloadable File (likely PDF)
Engine Management:
Fuel injection systems (EFI), ignition timing, diagnostics, and sensor calibration.
Cooling System:
Air-cooled engine specifications and maintenance.
Exhaust System:
Component identification, removal, and installation.
Brake System:
Hydraulic brake system inspection, pad replacement, fluid bleeding, and caliper service.
Suspension System:
Front fork service (oil change, seal replacement), rear shock absorber specifications and adjustments.
Wheel And Tire System:
Tire pressure, wear inspection, wheel bearing service, and tire replacement procedures.
Steering System:
Handlebar removal/installation, steering head bearing maintenance.
Body And Frame:
Fender removal/installation, fuel tank mounting, seat removal, and frame inspection.
Routine Maintenance:
Oil changes, filter replacements, spark plug servicing, drive belt inspection/adjustment, and lubrication points.
Component Overhaul:
Detailed procedures for engine, transmission, and carburetor/EFI system overhaul.
Troubleshooting:
Diagnostic charts and symptom-based troubleshooting guides for common issues.
Electrical Diagnostics:
Fault finding for ignition, charging, lighting, and accessory circuits.
Specification Tables:
Torque specifications, clearance measurements, fluid capacities, and electrical specifications.
Special Tools:
Identification of required Harley-Davidson special tools for specific repair procedures.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds. Includes diagnostic procedures.
Engine Family:
Evolution (Evo) V-Twin
Engine Type:
Air-cooled, 45-degree V-twin
Displacement Variants:
Commonly 883cc (53.9 cu in) and 1200cc (73.2 cu in) variants within this range.
Horsepower Range:
Approximately 55-67 hp (depending on displacement and tuning).
Torque Range:
Approximately 51-71 lb-ft (depending on displacement and tuning).
Fuel Delivery:
Electronic Fuel Injection (EFI) for models in this range, replacing carburetors on earlier models.
Fuel Type:
Unleaded gasoline, minimum octane rating specified by Harley-Davidson (typically 91).
Oil Type:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50 or equivalent motorcycle-specific oil meeting Harley-Davidson specifications.
Oil Capacity:
Approximately 3 quarts (2.8 liters) with filter change (refer to manual for exact capacity).
Gearbox:
5-speed constant mesh
Transmission Type:
N/A (All XL Sportsters in this era used the same core transmission design).
Drive Type:
Belt drive (final drive)
Clutch Type:
Wet, multi-plate
Transmission Fluid:
Harley-Davidson Transmission Fluid or equivalent SAE 80W-90 gear oil.
Transmission Fluid Capacity:
Approximately 1.5 pints (0.7 liters) (refer to manual for exact capacity).
Wheelbase:
Varies by model, typically around 59.6 inches (1514 mm).
Seat Height:
Varies by model, typically around 28 inches (711 mm) unladen.
Dry Weight:
Approximately 500-550 lbs (227-250 kg) depending on model and configuration.
Gross Vehicle Weight Rating:
Specified in manual, typically around 900-1000 lbs (408-454 kg).
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized like automotive).
Braking System:
Dual hydraulic disc brakes (front and rear) with single or dual piston calipers depending on model year.
Lighting:
Halogen headlight, LED taillight and brake light, turn signals.
Frame Construction:
Steel cradle frame.
Instrumentation:
Analog speedometer with integrated tachometer (on some models), odometer, trip meter, fuel gauge, and indicator lights.
Audio System:
Optional accessory audio systems available, not standard on all models.
ABS:
Anti-lock Braking System (ABS) available as an option on many models within this range.
Diagnostic Ports:
Data link connector (DLC) for diagnostic tools and software updates.
Initial Service:
First service typically around 1,000 miles (1,600 km).
Regular Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Drive Belt Tension Check:
Every 5,000 miles (8,000 km).
Spark Plug Replacement:
Refer to manual, typically every 10,000-15,000 miles (16,000-24,000 km).
Brake Fluid Type:
DOT 4 hydraulic fluid.
Primary Chain Case Fluid:
Harley-Davidson Primary Chain Case Lubricant or equivalent SAE 80W-90 gear oil.
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings.
Potential Electrical:
Occasional issues with charging system components (stator, regulator) or wiring harness integrity.
Fuel System Maintenance:
Regular inspection and cleaning of fuel injectors and fuel filter.
Brand Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running model families, known for its sporty character and accessible performance.
2004 Update:
The 2004 model year marked a significant update with the introduction of the rubber-mounted Evolution engine and a new frame, improving comfort and handling.
Manufacturing Location:
United States (Milwaukee, Wisconsin and Kansas City, Missouri primarily).
Model Recognition:
The Sportster line has consistently been recognized for its classic styling and customization potential.
Owner Satisfaction:
Generally high owner satisfaction, particularly among those who appreciate its raw character and customization.
Emission Standards:
Compliant with US EPA and California ARB emissions standards for the respective model years.
