Segment:
Cruiser motorcycle segment, specifically the custom-oriented Sportster line.
Competitors:
Competes with other mid-size V-twin cruisers from manufacturers like Indian Motorcycle and aftermarket customs.
Engine Characteristic:
Iconic Harley-Davidson Evolution V-twin engine known for its torque and distinctive sound.
Custom Styling:
Designed with customization in mind, featuring classic styling elements like chrome accents and a lower stance.
Engine:
Full engine disassembly, assembly, diagnosis, and repair procedures for the Evolution V-twin engine.
Transmission:
Service and repair of the transmission and clutch systems.
Fuel System:
Carburetor (if applicable for specific year) or fuel injection system diagnosis, cleaning, and repair.
Electrical System:
Wiring diagrams, component testing, charging system, ignition system, lighting, and accessories.
Suspension:
Front fork and rear shock absorber service, adjustment, and replacement.
Brakes:
Hydraulic brake system service, bleeding, pad replacement, and caliper repair.
Frame And Bodywork:
Frame inspection, body panel removal/installation, and component mounting.
Wheels And Tires:
Wheel bearing service, tire mounting/balancing, and spoke tension adjustment (if applicable).
Exhaust System:
Exhaust system inspection, repair, and replacement procedures.
Maintenance:
Scheduled maintenance, fluid changes, filter replacement, and lubrication.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Comprehensive instructions for dismantling and reassembling all major vehicle components.
Adjustments:
Carburetor tuning, chain adjustment, clutch and brake lever adjustments.
Installation:
Procedures for installing new or replacement parts and accessories.
Depth:
Comprehensive, covering from basic maintenance to in-depth engine rebuilds and electrical diagnostics.
Diagrams Illustrations:
Detailed pictorial diagrams, exploded views, and photographs guiding through service procedures.
Special Tools:
Identification and usage instructions for necessary special service tools.
Specifications:
Service data, factory specifications, allowable limits, and tightening torques for all components.
PDF Quality:
High-resolution, ensuring clarity of text and images.
Printability:
Fully printable, allowing users to print specific sections or the entire manual.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Operating Systems:
Windows, Mac, Linux OS compatible.
Software Requirement:
Adobe Reader required for viewing.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200 cc (73.2 cubic inches)
Bore X Stroke:
3.51 in. x 3.81 in. (89 mm x 96.8 mm)
Compression Ratio:
9.7:1 (Typical)
Horsepower:
Approximately 65-70 HP (estimated, varies with tuning and year)
Torque:
Approximately 70-75 ft-lbs @ 3500 RPM (estimated, varies with tuning and year)
Fuel Delivery:
Carburetor (e.g., Keihin CV) or Electronic Sequential Port Fuel Injection (ESPFI) depending on specific year within the 2004-2006 range.
Fuel Type:
Unleaded gasoline, 91 octane (RM)
Type:
5-speed constant mesh
Clutch:
Wet, multi-plate, high-performance clutch
Gear Ratios:
Specific ratios detailed within the manual.
Transmission Fluid:
Formula+, SAE 50 (Harley-Davidson recommendation).
Length:
Approximately 88.5 inches (2248 mm)
Width:
Approximately 35.0 inches (889 mm)
Height:
Approximately 48.2 inches (1224 mm)
Dry Weight:
Approximately 550 lbs (249 kg)
Gvwr:
Refer to motorcycle's VIN plate for specific Gross Vehicle Weight Rating.
Payload Capacity:
Refer to motorcycle's VIN plate for specific payload capacity.
Crash Test Ratings:
N/A (Motorcycles are not typically crash-tested by standardized bodies like NHTSA for cars.)
Braking System:
Dual-action, front and rear hydraulic disc brakes.
Lighting:
Halogen headlight, LED tail light, and incandescent turn signals.
Frame Construction:
Robust steel frame designed for stability and rider feedback.
Seat:
Comfortable solo seat, designed for rider support during longer rides.
Audio System:
N/A (Typically not equipped with factory audio systems on this model).
Gauges:
Analog speedometer with integrated tachometer (on some models), odometer, trip meter, and indicator lights.
ABS:
Anti-lock Braking System (ABS) was an optional feature, not standard on all models for these years. Manual would cover its service if equipped.
Bluetooth:
N/A (Not equipped with Bluetooth connectivity from the factory).
First Service:
Typically 1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for standard checks and fluid changes, with more intensive servicing at higher mileage intervals.
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 Synthetic (or equivalent meeting H-D specification).
Transmission Primary Chain Case Fluid:
Harley-Davidson Formula+, SAE 50.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specific viscosity and quantity detailed in manual (e.g., Harley-Davidson Genuine Fork Oil).
Carburetor Tuning:
Some models may require periodic carburetor adjustment for optimal performance and idle stability, especially if aftermarket exhausts or air cleaners are fitted.
Fuel Line Wear:
Inspect fuel lines for cracking or degradation, especially in warmer climates or with certain fuel blends.
Starter Solenoid:
Occasional issues with starter solenoid engagement, though generally reliable.
Regulator Rectifier:
While not prevalent in these specific years, it's a common Harley-Davidson component to monitor for potential failure leading to charging issues.
Heritage:
Part of Harley-Davidson's long-standing Sportster lineage, known for its accessible performance and customization potential.
Evolution 2004-2006:
These years represent a period where the Sportster platform continued to refine the Evolution engine, often incorporating fuel injection on later models and chassis updates.
Manufacturing Location:
USA (Harley-Davidson facilities)
Model Recognition:
The Sportster line has consistently been recognized for its iconic status and customizability within the motorcycle industry.
Reliability Ratings:
Generally considered reliable with proper maintenance, with owner satisfaction high due to the classic riding experience.
Certification:
Compliant with all applicable U.S. emissions and safety standards for its model year.
