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Harley Davidson XL1200L Sportster Low 2004-06 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley Davidson Model: XL1200L Sportster Low Model Variant: Sportster Low Years Covered: 2004, 2005, 2006 Codes Engine Family: Evolution (Big Twin) Chassis Code: XL 👋...
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类型: Motorcycle
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Harley Davidson XL1200L Sportster Low 2004-06 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley Davidson
Model:
XL1200L Sportster Low
Model Variant:
Sportster Low
Years Covered:
2004, 2005, 2006
Codes
Engine Family:
Evolution (Big Twin)
Chassis Code:
XL
👋 Introduction
Market Position
Target Audience:
Harley Davidson owners, DIY mechanics, professional motorcycle technicians
Competitive Analysis
Competitor Manuals:
Offers more comprehensive detail and clarity than basic owner's manuals or condensed service guides.
Key Features
Instant Access:
Instant download upon payment, no shipping delays or costs.
Ease Of Use:
Simple, easy-to-read explanations designed for both novice and experienced users.
Completeness:
Guaranteed 100% complete and intact, no missing or corrupt pages.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair, Maintenance, Troubleshooting, Adjustment, Disassembly, Assembly
Secondary Coverage:
Component diagnostics, service data, special tool usage, wear limits, safety precautions
Page Count
Total Pages:
462
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine specifications, disassembly, assembly, troubleshooting, lubrication, cooling system, fuel system, ignition system, exhaust system
Transmission:
Transmission disassembly, assembly, troubleshooting, lubrication, clutch operation
Drivetrain:
Primary drive, final drive belt inspection and adjustment, chain maintenance (if applicable)
Chassis:
Frame, suspension (front and rear), steering, wheels, tires, braking system (front and rear)
Electrical:
Battery, charging system, ignition system, lighting system, starting system, instrumentation, wiring diagrams, diagnostic procedures
Bodywork:
Body panel removal and installation, fenders, fuel tank, seat, mirrors, accessories
Controls:
Throttle controls, brake levers, clutch lever, shift lever, footpegs
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication points, battery care, tire pressure checks
Troubleshooting:
System-specific diagnostic trees, common problem identification and solutions
Repair:
Component repair, rebuild procedures, component replacement, overhaul instructions
Installation:
Component installation, accessory installation procedures
Disassembly:
Step-by-step disassembly of all major and minor components
Adjustment:
Carburetor adjustments, clutch adjustments, brake adjustments, suspension adjustments, idle speed adjustments
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical systems
Illustrations:
Pictorial diagrams, exploded views, detailed photographs, wiring schematics
Special Tools:
Identification and usage of specific Harley Davidson service tools
Torque Values:
Precise torque specifications for all fasteners
Wear Limits:
Serviceable wear limits for critical components
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows, Mac, Linux OS
Reader Requirement:
Adobe Reader
Print Quality
Printability:
Yes, all pages printable
Resolution:
High resolution, suitable for printing
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.2 cubic inches)
Bore X Stroke:
3.500 in x 3.8125 in (88.9 mm x 96.8 mm)
Compression Ratio:
9.0:1 (Typical for this era Sportster)
Performance
Horsepower:
Approx. 65-70 HP (Actual figures vary and are not explicitly stated in product description, but are typical for this model)
Torque:
Approx. 70-75 ft-lbs (Actual figures vary and are not explicitly stated in product description, but are typical for this model)
Fuel System
Fuel Delivery:
Carbureted (Keihin CV Carburetor on many models, potential for early EFI on some) - Manual will cover specific type.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/91 AKI
Lubrication
Oil Type:
Harley-Davidson 20W50 SYN3 or equivalent motorcycle-specific synthetic oil (refer to manual for exact specification)
Oil Capacity:
Approximately 3.0 US quarts (2.8 L) with filter change (verify in manual)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Optional
Optional Transmissions:
N/A for this specific model and year range
Features
Clutch Type:
Wet, multi-plate
Transmission Fluid:
Harley-Davidson Formula+ Transmission Lubricant or equivalent (verify in manual)
📐 Dimensions
Exterior
Overall Length:
Approx. 90.0 in (2286 mm)
Wheelbase:
Approx. 60.0 in (1524 mm)
Seat Height:
Approx. 26.3 in (668 mm)
Weights
Dry Weight:
Approx. 567 lbs (257 kg)
Gross Vehicle Weight Rating:
Approx. 965 lbs (438 kg)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are not subject to standardized automotive crash test ratings.
Active Features
Braking System:
Dual disc front, single disc rear hydraulic brakes (specifics detailed in manual)
Suspension Setup:
Tuned for a lower ride height and comfortable cruising (details on adjustment in manual)
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals (wiring and troubleshooting in manual)
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer (optional), odometer, trip meter, indicator lights (detailed in manual)
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature, check specific bike configuration. Manual will cover its operation and maintenance.
Connectivity
Connectivity Features:
Limited by era; primarily focused on mechanical and electrical systems. No modern Bluetooth or app integration.
🔧 Maintenance
Service Intervals
Initial Service:
First service typically around 1,000 miles (refer to manual for exact mileage and procedure)
Regular Maintenance:
Recommended intervals for oil changes, filter replacements, and other checks are detailed in the manual.
Fluid Specifications
Engine Oil:
Harley-Davidson 20W50 SYN3 or equivalent (refer to manual)
Transmission Fluid:
Harley-Davidson Formula+ or equivalent (refer to manual)
Primary Chain Case Fluid:
Harley-Davidson Formula+ or equivalent (refer to manual)
Brake Fluid:
DOT 4 (refer to manual for specific type and fluid level checks)
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, belt drive wear, spark plugs
Potential Electrical:
Wiring harness integrity, voltage regulator, stator (manual provides diagnostic steps)
Engine Performance:
Carburetor tuning, idle stability, ignition timing (manual covers adjustments)
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, a legendary American motorcycle manufacturer founded in 1903, known for its V-twin engines and iconic styling.
Model Evolution
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running model families, evolving significantly over the decades while maintaining its core identity.
Xl1200L Introduction:
The XL1200L 'Low' model was introduced to offer a more accessible and comfortable riding position, particularly for shorter riders, by lowering the seat height and suspension.
Production
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin)
🏆 Awards & Recognition
Recognitions
Awards:
No specific awards are listed for this manual. The Harley-Davidson Sportster line generally receives praise for its iconic style and V-twin character.
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