Harley-Davidson XL Sportster 2004–2013 Service & Repair Manual (Clymer)

This Clymer service and repair manual covers 2004–2013 Harley-Davidson XL Sportster models in the XL883 and XL1200 families. The 2007–2013 supplement gives the procedures and specifications unique to those models and refers back to the main chapters for shared work. Repair coverage is limited to the XL platform.

PDF Search, Bookmarks, and Page Coverage

Text search and diagram detail: The main text and wiring labels are searchable. The opening chapter page has no searchable text. Bookmarks jump to chapters, the supplement, and some wiring pages using filenames as labels. Zoom in to read small connector and pin labels.

One printable English PDF contains 598 pages, including 145 pages of supplemental service information and eight pages of color wiring diagrams. Printed pagination jumps from page 590 to page 596. Printed pages 591–595 are missing from the file.

Sportster Maintenance, Overhaul, and Fault Finding

These selected topics show the range of work covered. The manual also describes seat and side stand removal and installation.

• Maintenance and tune-up: Service lubricants, spark plugs, batteries, and tires. Check primary-chain and drive-belt tension and adjust clutch and throttle controls.
• Evolution engine overhaul: Remove and install the engine, service rocker boxes, heads, valves, cylinders, and pistons, and inspect cam timing, the oil pump, crankcase, and crankshaft bearings.
• Primary drive and transmission: Disassemble and inspect the clutch, shift drum and forks, mainshaft, and countershaft. Follow the matching main-drive-gear and bearing procedures.
• Fuel and emissions: Service the constant-velocity carburetor on early models and diagnose and repair the EFI fuel supply, induction module, injectors, and sensors on later models.
• Electrical diagnosis: Trace starting, charging, ignition, lighting, speedometer, and security faults with circuit tests, connector views, and flowcharts for symptoms with or without trouble codes.
• Chassis and brakes: Service wheels, hubs, bearings, spokes, tires, and the drive belt. Overhaul forks and service steering-head bearings, shocks, swingarm, calipers, master cylinders, and brake lines.
• Workshop reference: Find torque tables, fluid capacities, maintenance intervals, clearances, wear limits, electrical test values, special-tool numbers, numbered photos, and exploded assembly views.

The step-by-step procedures are written to guide owners working on a motorcycle for the first time. Internal engine, transmission, brake, and electronic work calls for the measuring equipment and special tools specified for the job.

Carburetor and EFI Service

The 2004–2006 chapters cover carburetor disassembly, inspection, and adjustment. For 2007–2013 EFI models, the supplement covers pressure relief, fuel-pump module service, injector and throttle-body work, and ECM and sensor testing. Exhaust work and California evaporative-emissions equipment are also covered.

Transmission Tools and Bearing Replacement

The main-drive-gear procedures specify HD-35316-B for 2004–2005 and HD-35316-C for 2006-on assemblies. The 2006-on procedure calls for replacing the main-drive-gear bearing after removal. The tool references also identify the HD-38515A clutch spring compressor and HD-46285 transmission assembly fixture, so you can check tooling before disassembly.

Electrical Diagrams and Model Changes

The wiring pages cover the 2004–2006 ignition control module, the 2007–2009 ECM and EFI circuits, and the 2010-on main harness. They also show the 2011-on XL1200C rear-lighting harness and hands-free security and anti-theft tracking circuits. Diagnostic sections cover TSM, TSSM, and HFSM systems and identify the HD-42682 breakout box for specified circuit checks.

Brakes and Chassis Differences

The manual specifies DOT 5 brake fluid for 2004–2006 models and DOT 4 for 2007–2013 models. It warns that mixing fluid types can cause brake failure. The brake chapter covers bleeding and flushing, and the supplement documents changes to forks, wheels, rear fenders, and brakes.

Sample EFI Pressure and Compression Specs

For 2007–2013 EFI models, the fuel-pressure test calls for a steady 55–62 psi (380–425 kPa) as engine speed changes from idle.

With the engine warm and the throttle fully open during cranking, the supplement lists 125–140 psi for 2007 XL883 models, 165–180 psi for 2008–2013 XL883 models, and 200–225 psi for 2007–2013 XL1200 models.