🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

2004-2006

Engine Family:

Evolution (Evo)

Chassis Code:

XL

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Owners and technicians of Harley-Davidson XL1200C Sportster Custom models from 2004-2006, seeking comprehensive repair and maintenance guidance.

Value Proposition:

Provides official factory-level repair information, crucial for accurate diagnostics and repairs, ensuring the longevity and performance of the Sportster Custom.

Authenticity:

Official Factory Service Repair Manual, ensuring accuracy and completeness of procedures and specifications.

Comprehensiveness:

Covers all aspects of maintenance, troubleshooting, and repair, making it an indispensable resource for any owner or mechanic.

📋 Manual Details

Primary Coverage:

Complete Factory Service Repair

Model Years Covered:

2004, 2005, 2006

Estimated Page Count:

Hundreds of Pages (Specific count not provided in description)

Manual Classification:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine System:

Complete disassembly, assembly, inspection, and repair of the Evolution 1200cc V-Twin engine, including top-end, bottom-end, lubrication, and cooling systems.

Fuel System:

Carburetor (Keihin CV 40mm) tuning, rebuilding, and diagnosis; fuel tank service, fuel filter replacement, fuel pump (if applicable to specific model year configuration).

Ignition System:

Ignition module testing and replacement, spark plug service, wiring diagrams for ignition components.

Transmission System:

5-speed constant mesh transmission service, clutch adjustment and replacement, primary drive maintenance, transmission fluid specifications and change intervals.

Drivetrain:

Belt drive system inspection, tension adjustment, and replacement; rear pulley and sprocket service.

Braking System:

Front and rear brake caliper service, brake pad replacement, brake fluid flush and bleeding procedures, master cylinder overhaul, brake line inspection.

Suspension System:

Front fork service (oil change, seal replacement, spring inspection), rear shock absorber inspection and replacement.

Electrical System:

Complete wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance and testing, lighting system service, diagnostic codes, switchgear troubleshooting.

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm bearing maintenance, wheel bearing replacement.

Bodywork And Trim:

Fender removal and installation, fuel tank removal and installation, seat service, handlebar and control adjustments.

Maintenance Procedures:

Scheduled maintenance tasks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, brake fluid changes, belt tension checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting.

Repair Procedures:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major vehicle systems.

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and carburetor overhauls.

Adjustment Procedures:

Carburetor idle/mixture, clutch, throttle, brake levers, belt tension, chain tension (if applicable to earlier models, though belt is standard).

Electrical Diagnostics:

Wiring harness troubleshooting, component testing (switches, sensors, actuators), voltage drop testing.

Depth Of Information:

Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Capabilities:

Includes diagnostic procedures, fault code tables, and troubleshooting flowcharts.

Rebuild Instructions:

Detailed instructions for complete engine and transmission rebuilds, including torque specifications and clearances.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely searchable text, enabling quick access to specific topics (common in high-quality factory PDFs).

Print Recommendation:

Printable on demand for workshop use. High-resolution images and diagrams.

Binding For Print:

N/A (Digital Download)

Paper For Print:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200cc (73.3 cubic inches)

Bore X Stroke:

3.500 in. x 3.812 in. (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Valve Train:

Overhead valve (OHV), two valves per cylinder, pushrod actuated.

Horsepower:

Approximately 65-68 hp @ 5200 rpm (Varies slightly by year and specific tuning).

Torque:

Approximately 70-72 ft-lbs @ 3500 rpm (Varies slightly by year and specific tuning).

Fuel Delivery:

Carbureted (Keihin CV 40mm)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

Oil Type:

Harley-Davidson SAE 20W-50 Premium Motorcycle Oil or equivalent meeting H-D specification.

Oil Capacity:

3.0 US qt. (2.8 L) with filter change.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive:

45-tooth, 1.375 inch wide belt drive.

Final Drive:

32-tooth, 1.375 inch wide belt drive.

Clutch Type:

Wet, multi-plate

Transmission Fluid Type:

Harley-Davidson Manual Transmission Lubricant (or equivalent meeting H-D specifications).

Transmission Fluid Capacity:

24 US fl oz. (0.7 L)

📐 Dimensions

Length:

Approx. 90.0 in. (2286 mm)

Width:

Approx. 35.0 in. (889 mm) (Handlebar width)

Height:

Approx. 48.0 in. (1219 mm) (Seat height variable)

Dry Weight:

Approx. 550 lbs (250 kg)

Gross Vehicle Weight Rating:

Approx. 960 lbs (435 kg)

Wheelbase:

Approx. 60.0 in. (1524 mm)

Ground Clearance:

Approx. 4.25 in. (108 mm)

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not subject to standardized crash test ratings in the same way as automobiles.

Braking System:

Dual-piston front caliper with 292mm disc, dual-piston rear caliper with 292mm disc. (ABS was not typically standard on this model year).

Lighting:

Halogen headlight, LED tail light, standard turn signals.

Frame Construction:

Steel frame and swingarm designed for stability.

Ergonomics:

Forward foot controls, drag-style handlebars, low seat height contribute to rider control and comfort.

💡 Technology Features

Audio System:

Base models typically did not feature integrated audio systems; aftermarket options are common.

Instrumentation:

Analog speedometer, tachometer, fuel gauge, and indicator lights. Odometer and trip meter functions.

Cruise Control:

Not typically available as standard equipment on the 2004-2006 XL1200C. Aftermarket options exist.

ABS:

Anti-lock Braking System (ABS) was generally not a standard or widely available option on the XL1200C during these model years.

Smartphone Integration:

N/A - No factory integration for smartphones.

Diagnostic Ports:

Features diagnostic connectors for engine management and fault code retrieval, covered in detail by the service manual.

🔧 Maintenance

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 Tension Check:

Every 5,000 miles (8,000 km).

Brake Fluid Flush:

Every 2 years.

Engine Oil Viscosity:

SAE 20W-50

Transmission Oil Type:

Harley-Davidson Manual Transmission Lubricant

Primary Chain Case Oil:

Harley-Davidson Primary Chain Case Oil or equivalent (shared with transmission)

Brake Fluid Type:

DOT 4

Carburetor Tuning:

CV carburetor can sometimes require fine-tuning for optimal performance and idle stability.

Belt Wear:

Regular inspection and proper tensioning of the drive belt are crucial to prevent premature wear or failure.

Charging System Components:

Stator and regulator/rectifier can be potential failure points over time, though generally robust on this era.

Suspension Bushings:

Rubber components in the suspension and steering head bearings can degrade with age and mileage, requiring replacement.

📚 Vehicle History

Manufacturer:

Harley-Davidson Motor Company

Legacy:

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 models, known for its blend of performance and classic styling.

Xl1200C Evolution:

The XL1200C Custom evolved from earlier Sportster models, gaining fuel injection in later years (post-2006) and various styling and performance updates. The 2004-2006 era represents a significant period for the Evolution engine's refinement.

Manufacturing Location:

United States (Various Harley-Davidson assembly plants)

Production Period Covered:

2004, 2005, 2006 model years.

🏆 Awards & Recognition

Model Reputation:

The Sportster line is consistently praised for its classic styling, V-twin rumble, and customizability, making it a perennial favorite in the cruiser segment.

Editorial Reviews:

Often reviewed positively for its accessible performance and iconic status. Specific awards for 2004-2006 models would be found in contemporary motorcycle publications.

Manual Authenticity Certification:

This is a factory service manual, implying it meets the standards and specifications set by Harley-Davidson for authorized service centers.