🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200R Sportster Roadster Model Year: 2004-2006 Generation Generation Code: XL Evolution Engine - 5-speed Transmission Codes Engine Code: XL1200R 👋 Introduction Market Position Target Audience: DIY enthusiasts and experienced mechanics seeking comprehensive repair and maintenance information. Competitive Analysis Advantage: Provides a digital, cost-effective alternative to traditional paper manuals, with the convenience of selective printing and broad device compatibility. Key Features Features: Complete official factory service manual, hundreds of pages, hundreds of photos and illustrations, step-by-step instructions, printable, compatible with all Windows and Mac devices, accessible via web browser. Illustrations: Hundreds of photos and illustrations are referenced, providing visual guidance for complex procedures. 📋 Manual Details Coverage Areas Covered Years: 2004, 2005, 2006 Covered Models: XL1200R Sportster Roadster Page Count Estimated Pages: Hundreds of pages (specific count not provided, but implies extensive detail) Manual Type Type: Factory Service Repair Manual (Workshop Manual) Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Major Systems: General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Engine Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagram Electrical System Detail: Includes detailed troubleshooting for ignition, lighting, charging system (stator, regulator, battery), starting system (starter motor, solenoid), and all accessory circuits. Chassis Components: Includes detailed information on frame, forks, handlebars, seat, fenders, and other bodywork components. Procedures Included Repair Procedures: Step-by-step instructions for complete disassembly, repair, and reassembly of all covered systems. Includes troubleshooting guidance. Diagnostic Procedures: Comprehensive diagnostic flowcharts and troubleshooting guides for common and uncommon issues across all vehicle systems. Engine Rebuild: Detailed instructions for engine disassembly, inspection of internal components (pistons, rings, valves, camshafts), reassembly, and tuning. Suspension Service: Instructions for fork seal replacement, oil changes, spring replacement, and rear shock absorber servicing or replacement. Brake System Service: Procedures for brake fluid flushes, caliper rebuilds, master cylinder servicing, and pad/rotor replacement. Fuel System Service: Carburetor disassembly, cleaning, adjustment, and rebuild kits. Fuel tank removal and cleaning procedures. Fuel filter replacement. Tire And Wheel Service: Information on tire inspection, replacement, wheel balancing, and spoke tensioning (if applicable to spoke wheels). Technical Depth Depth: Comprehensive, covering detailed procedures suitable for both DIY enthusiasts and experienced mechanics. Implies in-depth diagnostics and rebuild information. Torque Specifications: Includes critical torque specifications for all fasteners and assembly points, ensuring proper assembly and preventing damage. Wiring Diagrams: Comprehensive and detailed wiring diagrams for all electrical circuits, color-coded for easy identification and troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: PDF format typically allows for text searching of keywords, greatly enhancing the efficiency of finding specific information. Print Quality Printable: Yes, all pages are printable. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Evolution V-Twin, Air-Cooled Displacement: 1200cc (73.7 cubic inches) Bore X Stroke: 3.496 in. x 4.130 in. (88.8 mm x 104.9 mm) - *Standard for Evolution 1200* Valve Train: Overhead Valve (OHV), Pushrod actuated. Performance Horsepower: Approximately 65-70 HP (estimated for this era, specific figure not in product data) Torque: Approximately 70-75 ft-lbs (estimated for this era, specific figure not in product data) Fuel System Fuel Delivery: Carburetor (likely Keihin CV) for early models, potential for early fuel injection on later variants within this range, though the 'Roadster' designation often implies carburetion. Manual coverage will detail specific systems. Fuel Type: Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Transmission Type: 5-Speed Constant Mesh Clutch Type: Wet, multi-plate Features Drive Type: Primary drive: Duplex chain. Final drive: Belt drive. 📐 Dimensions Exterior Wheelbase: Approx. 60.0 inches (1524 mm) - *Typical for XL models of this era* Weights Dry Weight: Approx. 540 lbs (245 kg) - *Typical for XL1200R models* Gross Vehicle Weight Rating: Approx. 960 lbs (435 kg) - *Typical for XL models* 🛡️ Safety Features Ratings Crash Test Data: Motorcycles of this era are not typically subject to standardized crash testing like automobiles. Manual will cover mechanical safety systems. Active Features Braking System: Dual Piston Front Caliper with Single Disc, Dual Piston Rear Caliper with Single Disc. Specifics on rotor size and pad compounds will be in the manual. Passive Features Lighting: Halogen Headlight, Incandescent Taillight and Turn Signals. 💡 Technology Features Infotainment Audio System: Base models typically do not feature integrated audio systems. Aftermarket options are common. Gauges: Analog speedometer and tachometer, fuel gauge, indicator lights. Manual will cover gauge cluster troubleshooting. Driver Assistance Cruise Control: Not standard on most XL1200R models of this era. Aftermarket availability. Connectivity Bluetooth: Not available on stock models of this era. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 miles or 6 months, whichever comes first. Exact intervals and oil types are detailed in the manual. Primary Chain Tensioner: Inspection and adjustment as needed, particularly important...