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2004-2006 Harley-Davidson Sportster repair manual Preview image 1
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2004-2006 Harley-Davidson Sportster repair manual

Models covered in this manual:

  • Harley-Davidson Sportster XL 883
  • Harley-Davidson Sportster XL 883 Custom
  • Harley-Davidson Sportster XL 883 Low
  • Harley-Davidson Sportster XL 883R
  • Harley-Davidson Sportster XL 1200
  • Harley-Davidson Sportster XL 1200 Custom
  • Harley-Davidson Sportster XL 1200 Low
  • Harley-Davidson Sportster XL 1200 Roadster

Production/model years: 2004, 2005, 2006

File specifications

File size: 20.24 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 0.41 Minutes
$18.99 (incl. VAT) - Instant Download

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Product Information

Table of Contents:

Chapter One: General Information

  • Manual Organization
    • How to Use this Manual
  • Shop Safety
  • Shop Practices
  • Motorcycle Identification
  • Fasteners
  • Basic Tools
  • Specialized Tools
  • Service Fundamentals
  • Shop Supplies
  • Troubleshooting
  • Storage
  • Table 1: Fastener torque values
  • Table 2: Harley-Davidson model specifications
  • Table 3: Metric conversion table
  • Table 4: Wiring color codes
  • Table 5: Glossary of terms
  • Table 6: Engine oil
  • Table 7: Recommended lubricants and fluids
  • Table 8: Tire data

Chapter Two: Engine

  • Engine Service
  • Engine Disassembly
  • Engine Inspection
  • Engine Reassembly
  • Engine Installation

Chapter Three: Transmission

  • Transmission Service
  • Transmission Disassembly
  • Transmission Inspection
  • Transmission Reassembly
  • Transmission Installation

Chapter Four: Fuel and Exhaust Systems

  • Fuel System
  • Fuel Tank
  • Carburetor
  • Exhaust System

Chapter Five: Electrical System

  • Electrical Troubleshooting
  • Battery
  • Charging System
  • Ignition System
  • Starting System
  • Lighting
  • Switches
  • Wiring Diagrams

Chapter Six: Cooling System

  • Cooling System Overview
  • Radiator
  • Water Pump
  • Cooling Fan

Chapter Seven: Suspension and Steering

  • Front Suspension
  • Rear Suspension
  • Steering
  • Wheels
  • Tires

Chapter Eight: Brakes

  • Brake System Overview
  • Brake Maintenance
  • Brake Service
  • Brake Troubleshooting

Chapter Nine: Body and Frame

  • Frame Service
  • Body Panels
  • Seats
  • Windshields
  • Saddlebags

Chapter Ten: Maintenance

  • Maintenance Schedule
  • Lubrication
  • Tune-Up Procedures

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