Target Audience:
Harley Davidson Sportster owners and independent repair shops seeking detailed technical guidance.
Value Proposition:
Provides an inexpensive way to perform maintenance and repairs, saving significant costs compared to dealership service.
Features:
Comprehensive coverage for 2004-2006 models, detailed procedures, wiring diagrams, troubleshooting guidance.
Scope:
Complete service and repair coverage
Estimated Pages:
High (typically 500+ pages for comprehensive manuals of this era)
Type:
Workshop Service Repair Manual
Format:
Digital (PDF likely, given description, potentially printable)
Powertrain:
Engine, Fuel System, Ignition, Exhaust, Transmission, Clutch, Drive Belt
Chassis:
Frame, Suspension (Front and Rear), Steering, Brakes (Front and Rear), Wheels, Tires
Electrical:
Wiring Diagrams, Lighting, Instrumentation, Ignition System, Starting System, Charging System, Battery, Horn, EFI System Components
Body And Trim:
Body Panels, Seat, Handlebars, Controls, Fenders, Fuel Tank, Covers
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Tire Pressure, Chain Adjustment (if applicable), Spark Plug Service
Diagnostics Troubleshooting:
Fault Code Identification, Symptom-based Diagnostics, Component Testing
Repair Overhaul:
Engine Disassembly and Reassembly, Transmission Overhaul, Brake System Repairs, Suspension Component Replacement, Electrical Component Repair
Special Tools:
Identification and usage of Harley Davidson specific tools
Depth:
Comprehensive: Covers basic maintenance to complete engine and component overhauls, including detailed diagnostics and specifications.
Digital Quality:
High-resolution, searchable text, printable pages (assumed for workshop quality)
Print Readability:
Clear diagrams, legible text, industry-standard formatting (assumed for professional manual)
Binding:
N/A (for digital format), Perfect or Spiral Bound (if physical)
Paper Quality:
N/A (for digital format), Durable, coated paper stock (if physical)
Engine Family:
Evolution (Evo) V-Twin
Engine Displacement Options:
883cc (XL883), 1200cc (XL1200) - Specific model dependent
Engine Configuration:
45-degree V-twin, air-cooled
Bore X Stroke 883:
3.00 in x 3.81 in (76.2 mm x 96.8 mm)
Bore X Stroke 1200:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio 883:
8.4:1 (typical)
Compression Ratio 1200:
9.0:1 (typical)
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Ignition System:
Electronic Sequential Fuel Injection (EFI) with Electronic Spark Control (ESC) for 2004-2006 models.
Horsepower 883:
~53 hp @ 6000 rpm (estimated)
Torque 883:
~57 lb-ft @ 3500 rpm (estimated)
Horsepower 1200:
~65 hp @ 6000 rpm (estimated)
Torque 1200:
~71 lb-ft @ 3200 rpm (estimated)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Throttle Body
Fuel Type:
Unleaded Gasoline, 91 Octane Minimum Recommended
Fuel Tank Capacity:
3.1 gallons (11.7 Liters) for most models
Type:
5-speed Constant Mesh Manual
Clutch:
Multi-plate wet clutch
Final Drive:
Carbon fiber reinforced, belt drive
Gear Ratios:
Refer to specific manual for detailed gear ratios per model and year.
Transmission Fluid Type:
Harley Davidson Primary Chain Lubricant or equivalent SAE 20W-50.
Length:
Varies by model (e.g., ~88.0 in / 2235 mm for some models)
Width:
Varies by model (e.g., ~32.5 in / 825 mm)
Height:
Varies by model (e.g., ~45.5 in / 1155 mm)
Seat Height:
Varies by model (e.g., ~26.0 in / 660 mm unladen)
Dry Weight:
Approximately 560-570 lbs (254-259 kg) depending on model.
Gross Vehicle Weight Rating Gvwr:
Refer to VIN plate and manual for specific GVWR.
Safety Standards:
Meets all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.
Braking System:
Dual-piston caliper front brake, Single-piston caliper rear brake. (ABS typically not standard for these years).
Lighting:
Halogen Headlight, LED Tail/Brake Light, Amber Turn Signals.
Frame Construction:
Steel frame and swingarm for rigidity and durability.
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter for basic services. More frequent checks for specific components.
Engine Oil Type:
Harley Davidson Genuine SYN3 (Synthetic) 20W-50 or a high-quality motorcycle-specific 20W-50 synthetic/conventional oil.
Engine Oil Capacity:
Approx. 3.0 US quarts (2.8 Liters) with filter change.
Primary Chain Case Oil Type:
Harley Davidson Primary Chain Lubricant or SAE 20W-50 motorcycle oil.
Primary Chain Case Oil Capacity:
Refer to manual, typically around 1 quart (0.95 Liters).
Transmission Oil Type:
Harley Davidson Transmission Lubricant (Formula +) or equivalent SAE 50W.
Transmission Oil Capacity:
Refer to manual, typically around 20-24 fluid ounces (0.6-0.7 Liters).
Brake Fluid Type:
DOT 4 for front and rear brake systems (check manual for specific caliper compatibility).
Fork Oil Type:
Refer to manual for specific weight and type (e.g., Harley Davidson Type E or equivalent 10W).
Common Wear Items:
Clutch plates, wheel bearings, brake pads, belt drive components, primary chain tensioner.
Electrical Concerns:
Occasional issues with regulator/rectifier, battery charging system, and spark plug wire deterioration.
Engine Performance Quirks:
Tuning for optimal performance with EFI; potential for exhaust leaks at head pipe.
Heritage:
Harley Davidson, established 1903, renowned for its V-twin motorcycles and iconic American styling.
Sportster Lineage:
The Sportster line dates back to 1957, evolving from the K-model. The 2004 model year marked a significant redesign with a new frame and fuel injection.
Manufacturing Location:
United States
Production Period:
2004-2006 models represent a specific generation of the Sportster line.
