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Harley XL1200C Sportster Custom 2004-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Engine Variant: 883R (Note: Product description seems to incorrectly list 883R for XL1200C models. The manual covers XL1200C Custom, but the '883R' mention might be a listing error or an attempt to broaden appeal for 883 engine variants which are not the primary focus of this manual based on the 'XL1200C' designation.) Model Years: 2004, 2005, 2006 Codes Engine Family: Evolution (Sportster) 👋 Introduction Market Position Target Audience: DIY enthusiasts, home mechanics, and professional technicians working on Harley-Davidson XL1200C Sportster Custom motorcycles from 2004-2006. Competitive Analysis Advantage: Provides factory-level repair information in a convenient, cost-effective digital format, surpassing traditional paper manuals in accessibility and searchability. Key Features Content Scope: Complete official full factory service repair manual with hundreds of pages, covering all styles and procedures. Convenience: Instant download, no expiry dates, print-on-demand capability, accessible across multiple devices. Value Proposition Cost Savings: Enables owners to perform their own maintenance and repairs, saving significantly on labor costs charged by dealerships and independent mechanics. 📋 Manual Details Coverage Areas General Information: Yes Maintenance: Yes Chassis: Yes Fuel System: Yes Cooling System: Yes (Air-cooled) Engine: Yes Clutch: Yes Engine Lubrication: Yes Engine Removal Installation: Yes Drive System: Yes Transmission: Yes Wheels Tires: Yes Final Drive: Yes Brakes: Yes Suspension: Yes Steering: Yes Frame: Yes Electrical System: Yes Wiring Diagram: Yes Page Count Approximate Pages: Hundreds (Specific number not provided, but described as 'complete' and 'hundreds of pages') Manual Type Type: Factory Service Repair Manual / Workshop Manual Language Language: English Format Digital Format: PDF Accessibility: Compatible with Windows and Mac OS, accessible via web browser on PC, smartphone, and tablet Features: Printable (entire manual or specific pages), Searchable text (implied by PDF format) 📖 Manual Coverage Systems Covered Engine Details: Engine specifications, disassembly, reassembly, troubleshooting, lubrication, cooling (air-cooled). Drivetrain Transmission: Clutch operation and service, transmission components, operation, and maintenance, final drive belt inspection and replacement, drive sprocket and pulley service. Chassis Suspension Steering: Frame inspection and repair, suspension fork service (including fluid changes), shock absorber adjustments and replacement, steering head bearing maintenance and adjustment. Braking System: Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, rotor inspection and replacement. Electrical System: Battery service, charging system (stator, regulator/rectifier), ignition system components, lighting circuits, wiring harness diagnosis, electrical component troubleshooting. Fuel System: Carburetor (likely Keihin CV) disassembly, cleaning, adjustment, and troubleshooting. Fuel tank and petcock service. Wheels Tires: Wheel bearing service, tire inspection, pressure recommendations, and replacement procedures. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug service, belt tension checks, brake fluid flushes, tire pressure checks, cleaning and lubrication. Repair And Rebuild: Complete engine teardown and reassembly, transmission rebuilds, carburetor overhauls, brake system repairs, suspension component replacement, electrical system diagnostics and repair. Troubleshooting: Diagnostic flowcharts, identification of common problems, solutions for starting issues, running problems, electrical faults, and mechanical failures. Installation: Guidance for installing new parts, accessories, or performing engine/transmission swaps. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls. Detailed step-by-step instructions with photos and illustrations. 📊 Manual Specifications File Format Format: PDF Requirements: Adobe PDF Reader, Winzip (free download availability noted) Print Quality Printability: High-quality, printable pages for workshop use. Binding Type Binding: Not applicable (Digital PDF format) Paper Type Paper: Not applicable (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 45-degree V-twin, Evolution engine Displacement: 1200cc (73.4 cubic inches) Bore X Stroke: 3.496 in. x 3.812 in. (88.8 mm x 96.8 mm) - Standard for 1200cc Evolution Performance Horsepower: Approx. 65-70 HP (Estimated, as exact figures vary by year and tuning, but within the typical range for this engine in this era) Torque: Approx. 70-75 ft-lbs (Estimated, as exact figures vary by year and tuning) Fuel System Fuel Delivery: Carbureted (Likely Keihin CV, though early EFI models existed for Sportsters, the description implies a carbureted manual is most common for this era). Fuel Type: Unleaded Gasoline, Minimum 91 Octane (Premium) Ignition Ignition System: Electronic Ignition 🔧 Transmission Standard Type: 5-speed Manual Constant Mesh Features Clutch Type: Wet, multi-plate, diaphragm spring Final Drive Type: Belt Drive 📐 Dimensions Exterior Wheelbase: Approx. 60.0 inches (1524 mm) Weights Dry Weight: Approx. 540 lbs (245 kg) Gross Vehicle Weight Rating Gvwr: Approx. 940 lbs (426 kg) 🛡️ Safety Features Ratings Crash Test Results: Motorcycle safety ratings are typically not standardized or publicly available like automotive crash tests. Focus is on rider protection and handling. Active Features Braking System: Hydraulic front and rear disc brakes. Anti-lock Braking System (ABS) was an optional feature on some Sportster models during this period, though not explicitly mentioned for this specific manual's coverage. Passive Features Lighting: Headlight, taillight, brake lights, turn signals 💡 Technology Features Infotainment Audio System: Typically no integrated infotainment system or stereo on this...
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Harley XL1200C Sportster Custom 2004-2006 Service Repair ManualHarley XL1200C Sportster Custom 2004-2006 Service Repair ManualHarley XL1200C Sportster Custom 2004-2006 Service Repair ManualHarley XL1200C Sportster Custom 2004-2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL1200C Sportster Custom
Engine Variant:
883R (Note: Product description seems to incorrectly list 883R for XL1200C models. The manual covers XL1200C Custom, but the '883R' mention might be a listing error or an attempt to broaden appeal for 883 engine variants which are not the primary focus of this manual based on the 'XL1200C' designation.)
Model Years:
2004, 2005, 2006
Codes
Engine Family:
Evolution (Sportster)
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, home mechanics, and professional technicians working on Harley-Davidson XL1200C Sportster Custom motorcycles from 2004-2006.
Competitive Analysis
Advantage:
Provides factory-level repair information in a convenient, cost-effective digital format, surpassing traditional paper manuals in accessibility and searchability.
Key Features
Content Scope:
Complete official full factory service repair manual with hundreds of pages, covering all styles and procedures.
Convenience:
Instant download, no expiry dates, print-on-demand capability, accessible across multiple devices.
Value Proposition
Cost Savings:
Enables owners to perform their own maintenance and repairs, saving significantly on labor costs charged by dealerships and independent mechanics.
📋 Manual Details
Coverage Areas
General Information:
Yes
Maintenance:
Yes
Chassis:
Yes
Fuel System:
Yes
Cooling System:
Yes (Air-cooled)
Engine:
Yes
Clutch:
Yes
Engine Lubrication:
Yes
Engine Removal Installation:
Yes
Drive System:
Yes
Transmission:
Yes
Wheels Tires:
Yes
Final Drive:
Yes
Brakes:
Yes
Suspension:
Yes
Steering:
Yes
Frame:
Yes
Electrical System:
Yes
Wiring Diagram:
Yes
Page Count
Approximate Pages:
Hundreds (Specific number not provided, but described as 'complete' and 'hundreds of pages')
Manual Type
Type:
Factory Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
Accessibility:
Compatible with Windows and Mac OS, accessible via web browser on PC, smartphone, and tablet
Features:
Printable (entire manual or specific pages), Searchable text (implied by PDF format)
📖 Manual Coverage
Systems Covered
Engine Details:
Engine specifications, disassembly, reassembly, troubleshooting, lubrication, cooling (air-cooled).
Drivetrain Transmission:
Clutch operation and service, transmission components, operation, and maintenance, final drive belt inspection and replacement, drive sprocket and pulley service.
Chassis Suspension Steering:
Frame inspection and repair, suspension fork service (including fluid changes), shock absorber adjustments and replacement, steering head bearing maintenance and adjustment.
Braking System:
Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, rotor inspection and replacement.
Electrical System:
Battery service, charging system (stator, regulator/rectifier), ignition system components, lighting circuits, wiring harness diagnosis, electrical component troubleshooting.
Fuel System:
Carburetor (likely Keihin CV) disassembly, cleaning, adjustment, and troubleshooting. Fuel tank and petcock service.
Wheels Tires:
Wheel bearing service, tire inspection, pressure recommendations, and replacement procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug service, belt tension checks, brake fluid flushes, tire pressure checks, cleaning and lubrication.
Repair And Rebuild:
Complete engine teardown and reassembly, transmission rebuilds, carburetor overhauls, brake system repairs, suspension component replacement, electrical system diagnostics and repair.
Troubleshooting:
Diagnostic flowcharts, identification of common problems, solutions for starting issues, running problems, electrical faults, and mechanical failures.
Installation:
Guidance for installing new parts, accessories, or performing engine/transmission swaps.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls. Detailed step-by-step instructions with photos and illustrations.
📊 Manual Specifications
File Format
Format:
PDF
Requirements:
Adobe PDF Reader, Winzip (free download availability noted)
Print Quality
Printability:
High-quality, printable pages for workshop use.
Binding Type
Binding:
Not applicable (Digital PDF format)
Paper Type
Paper:
Not applicable (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, Evolution engine
Displacement:
1200cc (73.4 cubic inches)
Bore X Stroke:
3.496 in. x 3.812 in. (88.8 mm x 96.8 mm) - Standard for 1200cc Evolution
Performance
Horsepower:
Approx. 65-70 HP (Estimated, as exact figures vary by year and tuning, but within the typical range for this engine in this era)
Torque:
Approx. 70-75 ft-lbs (Estimated, as exact figures vary by year and tuning)
Fuel System
Fuel Delivery:
Carbureted (Likely Keihin CV, though early EFI models existed for Sportsters, the description implies a carbureted manual is most common for this era).
Fuel Type:
Unleaded Gasoline, Minimum 91 Octane (Premium)
Ignition
Ignition System:
Electronic Ignition
🔧 Transmission
Standard
Type:
5-speed Manual Constant Mesh
Features
Clutch Type:
Wet, multi-plate, diaphragm spring
Final Drive Type:
Belt Drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 60.0 inches (1524 mm)
Weights
Dry Weight:
Approx. 540 lbs (245 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 940 lbs (426 kg)
🛡️ Safety Features
Ratings
Crash Test Results:
Motorcycle safety ratings are typically not standardized or publicly available like automotive crash tests. Focus is on rider protection and handling.
Active Features
Braking System:
Hydraulic front and rear disc brakes. Anti-lock Braking System (ABS) was an optional feature on some Sportster models during this period, though not explicitly mentioned for this specific manual's coverage.
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals
💡 Technology Features
Infotainment
Audio System:
Typically no integrated infotainment system or stereo on this model; accessories may be available.
Gauges:
Analog speedometer, tachometer (optional or integrated depending on specific 'Custom' trim variations), fuel gauge (if equipped).
Driver Assistance
ABS:
Optional on some models, but not standard across the range for these years.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles or annually, whichever comes first (Refer to manual for precise interval and oil type).
Primary Chain Tension:
Check and adjust as needed, typically at 2,500-5,000 mile intervals (Refer to manual for specific procedure and spec).
Brake Fluid Flush:
Every 2 years (Refer to manual for precise interval and fluid specification).
Fluid Specifications
Engine Oil:
Harley-Davidson SYN3 (fully synthetic) or a premium 20W-50 motorcycle oil meeting Harley-Davidson specifications (Refer to manual for exact OEM recommendation, e.g., Harley-Davidson Genuine Oil 20W-50).
Primary Chain Case Oil:
Harley-Davidson Genuine Formula + Transmission and Primary Chaincase Lubricant (or equivalent spec oil, refer to manual).
Transmission Oil:
Harley-Davidson Genuine Formula + Transmission and Primary Chaincase Lubricant (or equivalent spec oil, refer to manual).
Brake Fluid:
DOT 4 (Refer to manual for specific Harley-Davidson approved fluid).
Known Issues
Primary Chain Tensioner:
Early models (pre-2007) of the Evolution Sportster used a spring-loaded hydraulic tensioner which could wear prematurely. Manual will cover inspection and replacement procedures.
Carburetor Adjustment:
CV carburetor can sometimes require fine-tuning for optimal performance and idle stability.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can lead to intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
Harley-Davidson Motor Company, a storied American motorcycle manufacturer with a legacy dating back to 1903.
Model Evolution
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model line. The XL1200C Custom represents a popular iteration focused on classic styling with modern performance for its era.
Production
Manufacturing Location:
Harley-Davidson motorcycles are primarily manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Model Reputation:
The Sportster line is a highly regarded and iconic motorcycle platform known for its customization potential and classic V-twin rumble.
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