This manual covers the XL1200R Sportster Roadster models produced between 2004 and 2006. Known for its performance-oriented riding experience within the iconic Sportster line, the XL1200R typically features upgraded suspension and braking components, appealing to riders who appreciate a sportier feel on a classic V-twin platform. Built with renowned engineering quality and reliability, this motorcycle represents a significant part of the brand's heritage, tracing its lineage back to the 1957 K-model successor. The Sportster Roadster is designed for cruising and offers a distinctive character that has made it a benchmark in the cruiser motorcycle market. This comprehensive workshop repair service manual, written in English, provides in-depth information for the maintenance, diagnosis, and repair of all XL1200R Sportster Roadster models from 2004-2006, including all specified engine, transmission, and trim variants. It covers a wide array of systems, from engine and drivetrain to chassis and electrical components, offering detailed procedures for scheduled maintenance, fluid changes, component disassembly and reassembly, and complex repairs. The manual is intended for professional technicians and experienced DIY mechanics, equipping them with the knowledge and step-by-step instructions necessary to effectively service and maintain their vehicle, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200R Sportster Roadster Model Variant: Sportster Roadster Years Covered: 2004, 2005, 2006 Codes Vin Code Range: Refer to Manual for Specific VIN Decoding 👋 Introduction Market Position Market Segment: Cruiser/Performance Cruiser Motorcycle Competitive Analysis Key Competitors: Other V-twin cruisers from brands like Indian, Victory, and custom motorcycle builders. Key Features Vehicle Usp: The Sportster Roadster typically offers a more performance-oriented riding experience within the Sportster line, often with upgraded suspension and braking components, appealing to riders who prefer a sportier feel on a classic V-twin platform. Manual Value Proposition Cost Savings Potential: Significant savings on repair and maintenance bills by enabling DIY servicing. Accessibility: Instant download provides immediate access to critical repair information, eliminating wait times. 📋 Manual Details Coverage Areas Covered Models: All XL1200R Sportster Roadster models for the specified years Covered Engines: All specified engine types for the XL1200R Covered Transmissions: All specified transmission types for the XL1200R Covered Trims: All trim levels of the XL1200R Sportster Roadster Page Count Page Count Estimate: Hundreds of Pages (Exact count not specified, but described as comprehensive) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine, Fuel System, Cooling System, Lubrication System Drivetrain Systems: Clutch, Drive, Transmission, Final Drive Chassis Systems: Chassis, Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System, Wiring Diagrams General Information: General Information, Maintenance Procedures Included Maintenance Procedures: Scheduled Maintenance, Fluid Changes, Filter Replacements Repair Procedures: Engine Rebuilds, Transmission Overhauls, Brake System Repairs, Suspension Adjustments, Electrical Troubleshooting Diagnostic Procedures: Troubleshooting, Fault Diagnosis, Electrical System Diagnostics Disassembly Assembly: Component Disassembly and Reassembly Installation Procedures: Component Installation Technical Depth Technical Depth: Comprehensive diagnostic, repair, and maintenance information; detailed diagrams and step-by-step instructions; intended for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Functionality: YES Binding Type Binding Type: Digital (PDF Download) Paper Type Paper Type: Not Applicable (Digital Format) Requirements Required Software: Adobe PDF Reader, WinZip (for extraction) Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-twin Displacement: 1200cc (73.4 cu in) Bore X Stroke: Refer to Manual for Specifics (Typically around 3.496 in x 3.812 in) Compression Ratio: Refer to Manual for Specifics (Typically around 9.7:1) Performance Horsepower: Refer to Manual for Specifics (Typically around 65-70 HP) Torque: Refer to Manual for Specifics (Typically around 70-75 ft-lbs) Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) Fuel Type: Unleaded gasoline, minimum 91 octane Lubrication System Oil Type: Refer to Manual for Specifics (Typically Harley-Davidson 20W-50 or equivalent) Oil Capacity: Refer to Manual for Specifics (Typically around 3.0 US quarts with filter change) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-plate Features Transmission Fluid Type: Refer to Manual for Specifics (Typically Harley-Davidson Formula+ or equivalent) Primary Drive: Duplex chain, rubber isolated drive Final Drive: Belt drive 📐 Dimensions Exterior Length: Refer to Manual for Specifics (Typically around 88.0 inches) Width: Refer to Manual for Specifics (Typically around 37.0 inches) Height: Refer to Manual for Specifics (Typically around 47.0 inches) Weights Dry Weight: Refer to Manual for Specifics (Typically around 545 lbs) Wet Weight: Refer to Manual for Specifics (Typically around 572 lbs) Gross Vehicle Weight Rating: Refer to Manual for Specifics Fuel Capacity Fuel Tank Capacity: Refer to Manual for Specifics (Typically around 4.0 gallons) 🛡️ Safety Features Ratings Safety Certifications: Compliant with applicable safety standards for its manufacturing period. Active Features Braking System: Dual-action front and rear disc brakes with hydraulic actuation. Suspension Features: Telescopic front forks and rear...