CHAPTER ONE
GENERAL INFORMATION
This detailed and comprehensive manual covers
2004-2006 Harley-Davidson XL Sportster models. The
text provides complete information on maintenance,
tune-up, repair and overhaul. Hundreds of photographs
and illustrations created during the complete disassembly
of the motorcycle guide the reader through every job. All
procedures are in step-by-step format and designed for the
reader who may be working on the motorcycle for the first
time.
MANUAL ORGANIZATION
A shop manual is a tool and, as in all Service manuals,
the
chapters are thumb tabbed for easy reference. Main
headings are listed in the table of contents and the index.
Frequently used specifications and capacities from the ta-
bles at the end of each individual chapter are listed in the
Quick Reference Data section at the front of the manual.
Specifications and capacities are provided in U.S. stan-
dard and metric units of measure.
During some of the procedures there will be references
to headings in other chapters or sections of the manual.
When a specific heading is called out in a step it will be
italicized as it appears in the manual. If a sub-heading is
indicated as being “in this section” it is located within the
same main heading. For example, the sub-heading Han
-
dling Gasoline Safely is located within the main heading
SAFETY.
This chapter provides general information on shop
safety, tools and their usage, service fundamentals and
shop supplies.
Tables 1-10 are located at the end of this chapter.
Table 1 lists motorcycle dimensions.
Table 2 lists motorcycle weight.
Table 3 lists fuel tank capacity.
Table 4 lists general torque specifications.
Table 5 lists conversion formulas.
Table 6 lists technical abbreviations.
Table 7 lists U.S. tap and drill sizes.
Table 8 lists metric tap and drill sizes.
Table 9 lists fraction, decimal and metric equivalents.
Table 10 lists special tools.
Chapter Two provides methods for quick and accurate
diagnosis of problems. Troubleshooting procedures pres-
ent typical symptoms and logical methods to pinpoint and
repair the problem.
Chapter Three explains all routine maintenance neces-
sary to keep the motorcycle running well. Chapter Three
also includes recommended tune-up procedures.
Subsequent chapters describe specific systems such as
engine, transmission, clutch, drive system, fuel and ex
-
haust systems, suspension and brakes.
1
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