2004-2006 Harley-Davidson Sportster Service Manual

Harley Davidson 2004-2006 Sportster Models Service Manual

This official service manual provides complete maintenance, service, repair, and diagnostics information for Harley Davidson Sportster models from 2004 to 2006. Covering essential systems such as engine top and lower end service, electrical diagnostics, transmission repair, and chassis maintenance, it is a must-have guide for professional technicians and dedicated Sportster owners.

Model Covers:

Harley Davidson 2004-2006 Sportster models:
XL 883
XL 883C – Sportster 883 Custom
XL 883L – Sportster 883 Low
XL 883R – Sportster 883R
XL 1200C – Sportster 1200 Custom
XL 1200R – Sportster 1200 Roadster
XL 1200L – Sportster 1200 Low

File Format: PDF

Size: 26.31 MB

No. of pages: 462

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

General Information and Troubleshooting

• Quick reference data, general specifications, and model identification
• Step-by-step troubleshooting for engine, transmission, and electrical issues

Lubrication, Maintenance, and Tune-up

• Service intervals, lubrication charts, and tune-up procedures
• Oil changes, filter replacements, and seasonal storage guidelines

Engine Top and Lower End Service

• Top-end disassembly and inspection, including heads, cylinders, and pistons
• Bottom-end repairs covering crankcase, flywheels, and breather system

Transmission, Clutch, and Primary Drive

• Clutch inspection, adjustment, and primary drive service
• Transmission internal shift mechanism disassembly and assembly

Fuel, Emission, and Exhaust Systems

• Fuel tank, fuel line, carburetor, and fuel injection system maintenance
• Emission controls and exhaust system servicing

Electrical System and Wiring Diagrams

• Battery care, starter system, and alternator service
• Lighting, switches, instrumentation, and complete wiring diagrams

Chassis, Suspension, and Brakes

• Front and rear suspension maintenance and repairs
• Brake system bleeding, caliper service, and disc inspection
• Wheels, tires, and drive belt servicing

Body and Frame

• Seat, fender, frame repairs, and cosmetic maintenance

This Harley Davidson 2004-2006 Sportster Service Manual is a critical resource offering in-depth service, precise diagnostics, and expert repair guidance for anyone maintaining or restoring a Harley Sportster from this era.