This manual provides comprehensive information for the XL1200L Sportster Low, covering production years 2004 through 2006. Known for its iconic Evolution V-Twin engine and accessible 'Low' riding profile, the XL1200L is designed for riders seeking classic American cruiser performance and style. This workshop repair service manual delves into the engineering quality and reliability that define the brand, offering insights into the model's chassis and engine specifications, including its air-cooled, 45-degree V-twin configuration. This factory workshop repair service manual is an indispensable resource for owners, mechanics, and technicians. It offers detailed, step-by-step procedures for maintenance, diagnosis, and repair of all systems, including the engine, fuel system, chassis, brakes, and electrical components. With hundreds of pages of diagrams and information, this manual ensures accurate and complete guidance, enabling effective troubleshooting and proper upkeep of your XL1200L Sportster Low. 🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200L Sportster Low Year: 2004-2006 Product Type: Workshop Repair Service Manual Product Format: PDF Download Codes Engine Code: Evolution V-Twin Chassis Code: XL 👋 Introduction Market Position Target Audience: Harley-Davidson XL1200L Sportster Low owners, mechanics, enthusiasts Value Proposition: Enables DIY repairs, saving significant costs; provides professional-level service information Competitive Analysis Manual Type Comparison: Equivalent to factory manuals, often superior to aftermarket options in detail and accuracy Key Features Key Selling Points: Completeness, accuracy, ease of use, instant access, cost savings Information Layout: Numbered instructions, bold figure numbers, detailed illustrations, enlarged insets 📋 Manual Details Coverage Areas Coverage: All Models/Engines/Trim/Transmissions Types for XL1200L Sportster Low 2004-2006 Page Count Estimated Pages: Hundreds of pages (as stated in product description) Manual Type Type: Factory Workshop Repair Service Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Printability: Full Printable Zoom Capability: Zoom IN/OUT Software Requirements: Adobe PDF Reader & WinZip Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered General Information: Included Maintenance: Included Chassis: Included Fuel System: Included Cooling System: Included Engine: Included Clutch: Included Engine Lubrication System: Included Engine Removal Installation: Included Drive System: Included Transmission: Included Wheels Tires: Included Final Drive: Included Brakes: Included Suspension: Included Steering: Included Frame: Included Electrical System: Included Wiring Diagrams: Included Procedures Included Diagnostic Procedures: Comprehensive Repair Procedures: Detailed, step-by-step Maintenance Procedures: Included Disassembly Assembly: Included Cleaning Reinstalling: Included Troubleshooting: Included, combined with electrical service Tool Requirements: Specified with procedures Technical Depth Depth: Professional, as used by local service/repair shops Accuracy: Original, accurate, and complete Content Quality: Hundreds of pages of diagrams and detailed information Information Access: Comprehensive diagnostic, repair, and maintenance information 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High quality, printable Binding Type Binding: N/A (Digital PDF Download) Paper Type Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Evolution V-Twin Displacement: 1200cc (approx. 73.2 cubic inches) Configuration: Air-cooled, 45-degree V-twin Performance Horsepower Estimate: Typically in the 60-70 HP range (specifics in manual) Torque Estimate: Typically in the 70-80 lb-ft range (specifics in manual) Fuel System Fuel Delivery: Fuel Injection (EFI) for models in this range, potentially Carbureted options depending on exact sub-model or market Fuel Type: Unleaded gasoline (specific octane rating in manual) 🔧 Transmission Standard Type: 5-speed constant mesh Optional Optional Transmissions: N/A (typically standard 5-speed for XL1200L) Features Drive Type: Belt Drive (final drive) 📐 Dimensions Exterior Seat Height Laden: Approx. 25.3 inches (643 mm) - designed for 'Low' profile Weights Dry Weight: Approx. 563 lbs (255 kg) - specific variations may exist Gross Vehicle Weight Rating: Specific GVWR would be detailed in the manual 🛡️ Safety Features Ratings Safety Standards: Meets relevant US DOT and EPA standards for motorcycles of the era Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Halogen headlight, taillight, stop light, turn signals 💡 Technology Features Infotainment Audio System: Base models typically do not include advanced infotainment; aftermarket options are common. Manual will detail any factory-fitted features for specific trims. Driver Assistance Rider Aids: Limited rider aids in this era; focus is on mechanical and electrical systems. Manual covers ABS if equipped (less common on early XL1200L). Connectivity Connectivity Features: No modern connectivity features like Bluetooth or smartphone integration from the factory. Manual focuses on core vehicle functions. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals (typically 5,000 miles or annually) Primary Chain Tensioner: Check and adjust as needed, specific intervals in manual Spark Plugs: Replace based on mileage or inspection (manual will specify) Fluid Specifications Engine Oil Type: Harley-Davidson recommended V-Twin specific oil (e.g., SAE 20W50 or similar, consult manual for exact spec) Primary Chain Case Oil: Harley-Davidson Primary Chain Case Lubricant or equivalent (manual will specify) Transmission Oil: Harley-Davidson transmission lubricant or equivalent (manual will specify) Brake Fluid: DOT 4 or DOT 5.1 hydraulic brake fluid (verify exact specification in manual) Known Issues Primary Chain Tensioner Wear:...