🏷️ 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: Hydraulic tensioner in the primary drive can wear out, leading to noise and potential damage. Manual will detail inspection and replacement. Carburetor Adjustment Idle Mixture: For carbureted models, proper idle mixture adjustment is crucial for smooth running. Manual provides precise procedures. Electrical Connections: Corrosion or loose connections can cause intermittent electrical issues. Manual's wiring diagrams are key. 📚 Vehicle History Brand Heritage Heritage: Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903. Model Evolution Sportster Lineage: The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving significantly over the decades. Xl1200L Introduction: The XL1200L 'Low' variant was introduced to cater to riders seeking a more accessible seat height and relaxed riding position. Production Production Period: Covered years: 2004, 2005, 2006