2004-2006 Harley-Davidson Sportster repair manual

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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