🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Model Line: XL Series Covered Years: 2004, 2005, 2006 Codes Product Identifier: HDS0406WSRM 👋 Introduction Market Position Positioning: Essential technical resource for owners and independent mechanics of Harley-Davidson Sportster models from the mid-2000s Competitive Analysis Alternatives: Factory Service Manuals (FSM), Haynes, Clymer manuals Advantage: Directly from factory-level data, offering the most accurate and comprehensive information for this specific generation Key Features Value Proposition: Empowers owners to perform detailed maintenance and repairs, saving on dealership costs and ensuring proper upkeep User Base: DIY mechanics, custom builders, Sportster enthusiasts 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Scope: Comprehensive maintenance, troubleshooting, and repair Page Count Estimated Pages: Approximately 500-700 (typical for this era's full service manuals) Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Evolution V-Twin (88ci/1450cc, 96ci/1584cc - depending on specific model variants within the range) Fuel System: Carbureted (Keihin CV type) and Electronic Fuel Injection (EFI) systems Ignition System: Electronic ignition, spark plugs, coils, ignition modules Transmission: 5-speed constant mesh transmission, clutch system, primary drive Drivetrain: Belt drive system, final drive belt maintenance Chassis: Frame, swingarm, suspension (front forks, rear shocks) Brakes: Front and rear hydraulic brake systems, calipers, master cylinders, lines, pads, rotors Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, switches, gauges Bodywork: Fuel tank, fenders, seat, handlebars, controls, minor body components Wheels And Tires: Wheel bearing maintenance, tire inspection and replacement, wheel specifications Lubrication: Engine oil, transmission oil, primary chaincase oil specifications and change procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), brake checks Engine Overhaul: Top-end rebuild, piston and cylinder replacement, valve adjustments, gasket replacements Transmission Repair: Clutch adjustments, transmission disassembly and reassembly, gear inspection Electrical Diagnostics: Troubleshooting electrical faults, testing components, wiring harness repair Brake Service: Brake bleeding, pad replacement, caliper service, master cylinder overhaul Suspension Service: Fork seal replacement, fork oil changes, rear shock absorber maintenance Fuel System Service: Carburetor tuning and rebuilding, fuel injector cleaning and testing (for EFI models) Troubleshooting Guides: Diagnostic charts for common symptoms and potential causes Technical Specifications: Torque values, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostic Level: Advanced diagnostics, including electrical system troubleshooting Rebuild Instructions: Detailed, step-by-step instructions for major component rebuilds 📊 Manual Specifications File Format Format Details: Digital PDF, typically searchable and printable Print Quality Quality: High-resolution scans of original factory manual pages Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Typically searchable PDF content ⚙️ Engine Specifications Primary Engine Engine Family: Harley-Davidson Evolution (V-Twin) Displacement: 88 cubic inches (1450cc) and potentially 96 cubic inches (1584cc) for later 2006 models (confirm specific sub-model) Configuration: Air-cooled, 45-degree V-twin, overhead valves (OHV) Bore X Stroke: 88ci: 3.50 in x 4.47 in (88.9 mm x 113.5 mm); 96ci: 3.75 in x 4.38 in (95.25 mm x 111.25 mm) - Check specific model for exact dimensions Performance Horsepower: Approximately 65-75 HP (Varies by year and specific model, e.g., XL1200C, XL883R) Torque: Approximately 70-85 ft-lbs (Varies by year and specific model) Fuel System Carbureted Model: Keihin CV (Constant Velocity) 40mm carburetor Efi Model: Electronic Fuel Injection (EFI) with Delphi/H-D ECU Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 ROZ Lubrication Oil Type: Harley-Davidson recommends specific motorcycle-grade synthetic or semi-synthetic oils, typically SAE 20W-50 Oil Capacity: Approximately 3 US quarts (2.8 liters) for engine and primary drive combined, check manual for exact figure Cooling System Method: Air-cooled Valve Train Actuation: Pushrod-actuated, overhead valves 🔧 Transmission Standard Type: 5-speed Constant Mesh Gear Ratios: Specific ratios are detailed in the manual, but generally provide a good balance for cruising and acceleration Optional Optional Types: N/A for this model year range (5-speed was standard) Features Primary Drive: HyVo chain drive in a separate oil bath (primary chaincase) Final Drive: Belt drive (45-tooth rear pulley, 32-tooth front sprocket) Fluid Type Transmission Oil: Harley-Davidson Formula + transmission & primary chaincase lubricant or equivalent SAE 50 motorcycle gear oil Fluid Capacity Transmission Capacity: Approximately 1 US quart (0.95 liters) for the primary chaincase, check manual 📐 Dimensions Exterior Wheelbase: Approx. 59.6 inches (1514 mm) for XL1200C, 57.1 inches (1450 mm) for XL883C Length: Varies by model (e.g., XL1200C approx. 89.7 inches / 2278 mm) Weights Dry Weight: Approx. 550-570 lbs (250-260 kg) depending on model Gvwr: Typically around 950-1000 lbs (430-455 kg) Cargo Cargo Capacity: Minimal, primarily rider and small accessories. Optional saddlebags available. 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles are not subjected to the same crash testing protocols as automobiles) Active Features Braking System: Hydraulic disc brakes, front and rear. ABS was not standard on most Sportsters in this era, but...