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2004-2006 Harley-Davidson Sportster XL manual

Includes the following models

  • 2004 Harley Davidson Sportster XL 883: 4A04xxx
  • 2004 Harley Davidson Sportster XL 1200: 4B04xxx
  • 2005 Harley Davidson Sportster XL 883: 5A05xxx
  • 2005 Harley Davidson Sportster XL 1200: 5B05xxx
  • 2006 Harley Davidson Sportster XL 883: 6A06xxx
  • 2006 Harley Davidson Sportster XL 1200: 6B06xxx

File specifications

File size: 22.99 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.47 Minutes
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Product Information

Table of Contents

  1. General Information

    • Introduction
    • Safety First
    • Model Identification
    • Specifications
    • Maintenance Schedule
    • Tools and Products
    • Motorcycle Storage
  2. Maintenance

    • Oil and Filter Change
    • Air Cleaner Inspection
    • Tire Inspection and Maintenance
    • Battery Maintenance
    • Spark Plug Inspection
    • Clutch Adjustment
    • Primary Chain Adjustment
    • Drive Belt Inspection
    • Brake System Inspection
    • Suspension Adjustment
    • Lubrication and Maintenance
  3. Chassis

    • Frame and Bodywork
    • Front Fork Maintenance
    • Rear Shock Absorbers
    • Wheels and Tires
    • Brakes
    • Clutch Cable Adjustment
    • Steering Head Bearings
  4. Engine

    • Engine Overhaul
    • Cylinder Head and Valves
    • Camshafts
    • Cylinder and Piston
    • Clutch Assembly
    • Gearshift Mechanism
    • Engine Removal and Installation
  5. Fuel System

    • Carburetor Adjustment
    • Carburetor Overhaul
    • Fuel Injection (EFI Models)
    • Fuel Tank and Lines
    • Exhaust System
  6. Cooling System

    • (For models equipped with cooling systems)
    • Radiator and Coolant
    • Water Pump
  7. Electrical System

    • Ignition System
    • Charging System
    • Starting System
    • Lights and Instruments
    • Switches
    • Electrical Components
    • Wiring Diagrams
  8. Wheels, Hubs, and Tires

    • Wheel Removal and Installation
    • Hub Overhaul
    • Tire Replacement
  9. Brakes

    • Brake Pad Replacement
    • Master Cylinder Overhaul
    • Brake Calipers
    • Brake Lines and Hoses
    • ABS System (if applicable)
  10. Clutch and Driveline

    • Clutch Assembly
    • Transmission
    • Primary Drive
    • Final Drive
  11. Troubleshooting

    • Engine Troubleshooting
    • Electrical Troubleshooting
    • Fuel System Troubleshooting
    • Chassis Troubleshooting
  12. Appendix

    • Torque Specifications
    • Service Data
    • Special Tools
    • Wiring Diagrams

The 2004-2006 Harley Davidson Sportster XL manual is a valuable resource for mechanics, technicians, and owners, providing detailed information and instructions for maintenance, repair, and troubleshooting of the motorcycle.

  • The pricing for this manual, handbooks, and repair guides is determined by the seller and may vary across different platforms. It is recommended to compare prices before making a purchase.
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Manuals frequently bought together

2005 Harley Davidson XL 883 L Sportster Low Rider, XL 883 C Sportster Custom, XL 883 Sportster, XL 1200 R Sportster Roadster, XL 1200 C Sportster Custom manual

  • 2005 Harley-Davidson XL 883 L Sportster Low Rider
  • 2005 Harley-Davidson XL 883 C Sportster Custom
  • 2005 Harley-Davidson XL 883 Sportster
  • 2005 Harley-Davidson XL 1200

2009 Harley Davidson Sportster, XL 883, XL 883C, XL 883L, XL 883N, XL 883R, XL 1200C, 1200L, XL 1200N, XL 1200R, R 1200 manual

  • 2009 Harley-Davidson XL 883 Sportster 883
  • 2009 Harley-Davidson XL 883C Sportster 883 Custom
  • 2009 Harley-Davidson XL 883L Sportster 883 Low
  • 2009 Harley-Davidson XL 8

2007 Harley Davidson Sportster XL 883R, XL 883L, XL 883C, XL 883, XL 1200R, XL 1200L, XL 1200C manual

  • 2007 Harley-Davidson XL 883R Sportster 883 R
  • 2007 Harley-Davidson XL 883L Sportster 883 Low
  • 2007 Harley-Davidson XL 883C Sportster 883 Custom
  • 2007 Harley-Davidson X

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