This manual provides comprehensive service and repair information for the XL Sportster models produced between 2004 and 2013. The XL Sportster, powered by the air-cooled Evolution V-Twin engine, available in 883cc and 1200cc configurations, is renowned for its iconic styling, accessible performance, and extensive customization potential. This generation features significant electronic integration, including Electronic Sequential Port Fuel Injection (ESPFI), and is built upon a heritage of American motorcycle engineering, offering a robust platform for both commuting and touring. This workshop repair service manual is designed to guide owners, mechanics, and technicians through all aspects of maintaining and repairing the XL Sportster. It covers a wide range of systems, including engine overhaul, transmission service, electrical diagnostics, brake system maintenance, and suspension adjustments. With detailed procedures, troubleshooting guides, and technical specifications such as torque values and fluid capacities, this manual ensures the longevity and optimal performance of your motorcycle. 🏷️ Basic Information Identification Make: Harley-Davidson Model: XL Sportster Model Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Codes Vin Code: 1HD1XX... 👋 Introduction Market Position Segment: Cruiser/Custom Motorcycle Target Audience: Owners and mechanics performing maintenance and repairs on Harley-Davidson XL Sportster models. Competitive Analysis Competitors: Manuals for other American V-twin motorcycles, as well as Japanese and European cruisers. Key Features Manual Strength: Comprehensive coverage, detailed diagrams, and step-by-step procedures essential for maintaining and repairing the Sportster platform. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, maintenance, and troubleshooting for the Harley-Davidson XL Sportster. Page Count Estimated Pages: 600-800 Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, top-end rebuild, lubrication system, cooling system (air-cooled specific details), fuel injection system (EFI), ignition system, starting system, charging system. Transmission: Clutch service, transmission overhaul, gear inspection, shift linkage adjustment, primary drive maintenance. Electrical: Wiring diagrams, component testing, lighting system, instrumentation, battery management, security system, handlebar controls, ECU diagnostics. Brakes: Front and rear brake system overhaul, hydraulic component replacement, bleeding procedures, brake pad and rotor specifications. Suspension: Front fork service (telescopic forks), rear shock absorber replacement and adjustment, swingarm service, wheel bearing maintenance. Frame And Body: Frame inspection, body panel removal/installation, fuel tank service, seat assembly, fenders, exhaust system. Wheel And Tire: Wheel and tire inspection, spoke tension, balancing, valve stem replacement. Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter service, chain adjustment (if applicable to specific sub-models), brake fluid flush, battery maintenance. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common electrical and mechanical faults, diagnostic trouble codes (DTCs) and their meanings. Repair And Rebuild: Detailed instructions for engine component disassembly, inspection, and reassembly; transmission rebuild; suspension fork rebuild; brake caliper overhaul. Technical Specifications: Torque specifications for all fasteners, engine timing procedures, valve clearance adjustment (if applicable to model variants), fluid capacities, electrical resistance values. Technical Depth Depth: Detailed enough for professional mechanics and experienced DIY enthusiasts. Covers complete engine rebuilds, transmission overhauls, and complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable for quick access to specific topics. Print Quality Resolution: Typically high-resolution, allowing for clear viewing of diagrams and text. Binding Type Binding: N/A (PDF Download) Paper Type Paper: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Family: Evolution (Evo) V-Twin Displacement Options: Primarily 883cc (57.5 cu in) and 1200cc (73.2 cu in) Evolution engines for this period. Cooling System: Air-cooled Bore X Stroke 883: 76.2 mm x 96.8 mm (3.00 in x 3.81 in) Bore X Stroke 1200: 88.9 mm x 96.8 mm (3.50 in x 3.81 in) Performance Horsepower 883 Approx: 50-55 HP Torque 883 Approx: 55-60 lb-ft Horsepower 1200 Approx: 65-70 HP Torque 1200 Approx: 70-75 lb-ft Fuel System Fuel Delivery: Electronic Sequential Port Fuel Injection (ESPFI) for most models in this range. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 (AKI) recommended. Engine Layout Cylinder Arrangement: 45-degree V-twin 🔧 Transmission Standard Type: 5-speed constant mesh sequential manual transmission Optional Availability: N/A for this generation of Sportster. Features Primary Drive: Enclosed, wet, multi-plate clutch. Primary drive via duplex chain. Final Drive: Belt drive Fluid Specifications Primary Chain Case Oil: Harley-Davidson Formula+ (or equivalent API GL-4, SAE 50, non-synthetic motor oil for primary) - Capacity approx. 2.4 quarts (2.3L). Transmission Oil: Harley-Davidson transmission lubricant or equivalent API GL-5, SAE 80W-90 gear oil - Capacity approx. 1 quart (0.95L). 📐 Dimensions Exterior Length Approx: 2,240 mm (88.2 in) for 1200 Custom Wheelbase Approx: 1,560 mm (61.4 in) Weights Dry Weight Approx 883: 254 kg (560 lbs) Dry Weight Approx 1200: 261 kg (575 lbs) Gvwr Approx: 431 kg (950 lbs) Fuel Capacity Approx: 12.5 L (3.3 US gal) 🛡️ Safety Features Ratings Safety Certification: DOT, EPA, CARB compliant. Active Features Braking System: Dual-piston front caliper, single-piston rear caliper. Optional ABS available on...