🏷️ Basic Information

Make:

Harley-Davidson

Model:

XL1200R Sportster Roadster

Model Variant:

Sportster Roadster

Engine Family:

Evolution (Big Twin Sportster)

Generation Code:

XL (Evo Sportster)

👋 Introduction

Positioning:

The XL1200R Sportster Roadster was positioned as a more performance-oriented, classic-styled cruiser within Harley-Davidson's Sportster line, appealing to riders who desired a blend of traditional Harley aesthetics with capable handling.

Competitors:

Competed with other American V-twin cruisers and some Japanese V-twin models offering similar styling and performance characteristics in the mid-weight cruiser segment.

Features:

High-performance Evolution V-twin engine, dual front disc brakes (a key differentiator for the 'R' model), tuned suspension for enhanced handling, classic Sportster styling, wide handlebars, and a comfortable riding position.

📋 Manual Details

Applicable Years:

2004, 2005, 2006

Total Pages:

462

Type:

Workshop Service Manual / Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, diagnosis, testing, adjustments, disassembly, assembly, troubleshooting, torque specifications, wear limits.

Transmission:

Service, repair, disassembly, assembly, adjustments, fluid types, capacities, troubleshooting.

Fuel System:

Carburetor (Keihin CV), fuel injection (if applicable for the specified years), fuel pump, fuel lines, fuel tank maintenance, cleaning, and troubleshooting.

Electrical System:

Ignition system, starting system, charging system, lighting, instruments, wiring diagrams, troubleshooting electrical faults, component testing.

Chassis And Suspension:

Front fork (showa type for R model), rear shock absorbers, wheel bearings, steering system, swingarm, maintenance, repair, and specifications.

Brakes:

Front and rear brake systems, hydraulic components, caliper service, brake fluid specifications, bleeding procedures, troubleshooting.

Bodywork And Trim:

Fenders, fuel tank, seat, handlebars, controls, minor body panel removal and installation, cosmetic repair guidance.

Maintenance:

Scheduled maintenance, fluid changes (oil, brake fluid), filter replacements, lubrication, adjustments, tune-ups.

Repair:

Step-by-step repair procedures for all major components and systems, including detailed disassembly and assembly instructions.

Troubleshooting:

Systematic diagnostic procedures, common problem identification, and solutions for various issues.

Special Tools:

Identification and usage of specialized tools required for specific service and repair operations, including relevant tool numbers.

Depth:

Comprehensive 'bumper to bumper' coverage, suitable for both DIY mechanics and professional technicians. Includes detailed explanations, pictorial diagrams, and factory specifications.

📊 Manual Specifications

Printability:

Yes, all pages are printable.

Searchability:

Implied by PDF format, though not explicitly stated as text-searchable. Likely image-based scans, but designed for reference.

Compatibility:

Windows, Mac, Linux OS (requires Adobe Reader).

Quality Description:

High-quality digital reproduction of the original workshop manual, designed for clarity and ease of use. Includes detailed illustrations and diagrams.

Binding:

Not Applicable (Digital PDF Download)

Paper:

Not Applicable (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200 cc (73.4 cubic inches)

Bore X Stroke:

3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

8.8:1 (typical for this era)

Valve Train:

Overhead valves (OHV), pushrod-actuated

Horsepower:

Approx. 65-70 HP (estimated, varies by specific model year and tuning)

Torque:

Approx. 70-75 ft-lbs (estimated, varies by specific model year and tuning)

Carburetor:

Keihin CV (Constant Velocity) 40mm

Fuel Delivery:

Gravity Feed (from fuel tank to carburetor)

Type:

Electronic ignition with dual spark plugs per cylinder (typically)

Type:

Dry Sump (oil tank separate from crankcase)

Oil Capacity:

Approx. 3.0 US quarts (2.8 liters) including filter

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Final Drive:

Belt Drive

Gear Ratios:

Specific gear ratios would be detailed in the manual, crucial for performance tuning.

📐 Dimensions

Wheelbase:

Approx. 60.0 inches (1524 mm)

Overall Length:

Approx. 88.0 inches (2235 mm)

Fuel Tank Capacity:

Approx. 4.5 US gallons (17 liters)

Dry Weight:

Approx. 545 lbs (247 kg)

Gross Vehicle Weight Rating:

Not explicitly stated, but the manual would contain this information.

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycle, crash testing standards differ significantly from automobiles)

Braking:

Dual 292mm front discs with 4-piston calipers, Single 292mm rear disc with 2-piston caliper. ABS typically not standard on these models.

Lighting:

Halogen headlight, LED taillight and brake light, standard turn signals.

Chassis Construction:

Steel frame and swingarm, designed for stability and rider feedback.

💡 Technology Features

Infotainment System:

Basic instrumental cluster: speedometer, tachometer (on some R models), odometer, trip meter, fuel gauge, warning lights. No advanced infotainment systems typically found.

Driver Assistance Features:

None typical for this era and model. Focus is on mechanical and rider interaction.

Connectivity Options:

No integrated connectivity features (e.g., Bluetooth, smartphone integration).

🔧 Maintenance

Oil Change:

Typically every 5,000 miles (8,000 km) or annually, whichever comes first. Manual will specify exact intervals and conditions.

Primary Chain Case Oil:

Typically every 10,000 miles (16,000 km). Manual will specify type and quantity.

Transmission Oil:

Typically every 10,000 miles (16,000 km). Manual will specify type and quantity.

Spark Plugs:

Inspection at regular intervals, replacement as needed, typically based on mileage or condition. Manual will provide specifications.

Engine Oil Type:

Harley-Davidson 20W50 V-Twin Motorcycle Oil (or equivalent meeting Harley-Davidson specifications).

Primary Chain Case Oil:

Harley-Davidson Primary Chaincase Lubricant (or equivalent meeting specifications).

Transmission Oil:

Harley-Davidson Transmission Lubricant (or equivalent meeting specifications, often a different viscosity than primary oil).

Brake Fluid:

DOT 4 hydraulic fluid (for brake systems).

Carburetor Tuning:

Keihin CV carburetors can sometimes require fine-tuning for optimal performance, especially after modifications or at higher altitudes. Manual provides baseline settings.

Belt Drive Tension:

Proper belt tension is crucial for longevity and performance. Manual details correct tensioning procedures.

Electrical Connections:

As with many older vehicles, checking and cleaning electrical connections can prevent common issues like intermittent power or starting problems.

Vibration:

While Evo engines are improved, some characteristic V-twin vibration is normal. Excessive vibration may indicate an imbalance or issue detailed in the manual.

📚 Vehicle History

Heritage:

Harley-Davidson has a long and storied history dating back to 1903, with the Sportster line being one of its longest-running and most iconic models, introduced in 1957.

Evolution Sportster:

The Evolution engine (Evo) was introduced in 1986, significantly improving performance, reliability, and reducing vibration compared to previous Sportster engines. The 'R' designation typically denotes a sportier, more performance-focused variant within the Sportster family.

Manufacturing Location:

United States (Harley-Davidson manufacturing facilities)

🏆 Awards & Recognition

Model Recognition:

The Harley-Davidson Sportster line, in general, has received numerous accolades over its history for its iconic status and V-twin performance. The XL1200R specifically is recognized for its enthusiast appeal.

User Satisfaction:

Generally high among Harley-Davidson enthusiasts who appreciate the classic styling and the Evo engine's character.

Manual Certification:

This manual is presented as a 'QUALITY manual' that is '100 percent COMPLETE and INTACT,' ensuring all necessary information is present for effective repair.