The Harley Davidson Sportster 2004-2006 Service Repair Manual is your essential resource for maintaining and repairing your motorcycle. This comprehensive manual provides detailed step-by-step instructions and clear illustrations, making it easy for both novice and experienced mechanics to tackle a wide range of repair tasks.

This service manual covers everything from routine maintenance procedures to complex engine repairs. You'll find detailed information on:

* **General Information:** Learn about your Sportster's specifications, safety precautions, and essential operating procedures.
* **Maintenance:** Master routine maintenance tasks such as oil changes, filter replacements, and tire pressure checks.
* **Chassis:** Understand the components and workings of your motorcycle's chassis, including the frame, swingarm, and suspension.
* **Fuel System:** Diagnose and repair issues related to fuel delivery, including the carburetor, fuel lines, and fuel tank.
* **Cooling System:** Learn how to maintain and repair your Sportster's cooling system, including the radiator, thermostat, and coolant.
* **Engine:** Dive deep into the engine, covering everything from valve adjustments and piston replacement to camshaft timing and crankshaft repairs.
* **Clutch:** Understand the workings of your clutch system and learn how to diagnose and fix clutch slippage or other problems.
* **Engine Lubrication System:** Maintain and repair your engine's lubrication system, including the oil pump, oil filter, and oil lines.
* **Engine Removal/Installation:** Learn the proper procedures for removing and installing your Sportster's engine.
* **Drive:** Understand the components and operation of your Sportster's drive system, including the transmission and final drive.
* **Transmission:** Diagnose and repair issues related to your Sportster's transmission, including gear shifting problems and gear replacement.
* **Wheels/Tires:** Learn how to maintain and repair your Sportster's wheels and tires, including tire replacement, wheel balancing, and spoke adjustments.
* **Final Drive:** Understand the workings of your Sportster's final drive system and learn how to diagnose and repair issues.
* **Brakes:** Diagnose and repair problems with your Sportster's braking system, including brake pads, calipers, and master cylinder.
* **Suspension:** Understand the components and operation of your Sportster's suspension system and learn how to diagnose and repair issues.
* **Steering:** Learn how to diagnose and repair steering problems, including issues with the steering head, forks, and handlebars.
* **Frame:** Understand the components and construction of your Sportster's frame and learn how to diagnose and repair frame damage.
* **Electrical System:** Diagnose and repair problems with your Sportster's electrical system, including the battery, starter, alternator, and wiring.
* **Wiring Diagrams:** Use detailed wiring diagrams to trace electrical circuits and troubleshoot problems.

With this comprehensive manual, you'll have the knowledge and tools to keep your Harley Davidson Sportster running smoothly and reliably.

The Harley-Davidson Sportster, a motorcycle model that has been a cornerstone of the iconic American brand since 1957, underwent significant changes for the 2004-2006 model years, with the introduction of the Evolution engine. This update brought with it improved performance and reliability, catering to both experienced riders and newcomers. The 2004-2006 Sportsters were offered in a range of configurations, from the classic XL883 and XL1200 models to the more specialized XL1200R Roadster and XL1200C Custom. While retaining the Sportster's traditional styling, these models incorporated modern touches such as a new fuel-injected engine, a redesigned swingarm, and updated front forks. These improvements further enhanced the Sportster's iconic blend of classic design with modern performance.

The 2004-2006 Sportsters were praised for their smooth handling, comfortable riding position, and user-friendly nature. They quickly became a popular choice for both short commutes and long-distance touring. The introduction of the Evolution engine yielded a significant increase in power and torque, while the updated suspension provided a more refined ride. However, as with any complex piece of machinery, regular servicing and maintenance are essential for ensuring optimal performance, reliability, and safety. This is where a comprehensive service repair manual becomes indispensable. The Harley Sportster 2004-2006 Service Repair Manual provides detailed instructions and diagrams for every aspect of maintenance, repair, and troubleshooting. From basic oil changes to more complex engine rebuilds, this manual equips owners with the necessary knowledge and guidance to keep their Sportsters running smoothly for years to come.