Harley-Davidson Sportster XL883, XL1200 Repair Manual 2004-2009

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Item # M427-2  ISBN: 9781599692876




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This repair and service manual covers Harley-Davidson XL Sportster models, 2004 to 2009 including:

• XL883 2004-2009
• XL883C 2004-2009
• XL883L 2004-2009
• XL883N 2009
• XL883R 2004-2009
  
  
• XL1200C 2004-2009
• XL1200L 2004-2009
• XL1200N 2007-2009
• XL1200R 2004-2009

Note: this manual does not include XR1200.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Engine operating requirements | Engine starting | Engine performance | Starting system | Charging system | Ignition system | Electronic diagnostic system | Fuel system | Engine noises | Engine lubrication | Clutch | Transmission | Excessive vibration | Suspension and steering | Brakes | Specifications

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type | Pre-ride inspection | Tires and wheels | Periodic lubrication | Periodic maintenance | Tune-up | Air filter element | Engine compression test | Spark plugs | Idle speed adjustment | Specifications

CHAPTER FOUR: ENGINE TOP END
Outer rocker covers | Inner rocker covers | Cylinder head | Valves and valve components | Pushrods and covers | Cylinder | Pistons and piston rings | Oil tank and oil hoses | Specifications

CHAPTER FIVE: ENGINE LOWER END
Engine | Valve tappets | Gearcase cover and timing gears | Oil pump | Oil filter mount | Crankcase and crankshaft | Engine mounting system | Specifications

CHAPTER SIX: PRIMARY DRIVE, CLUTCH AND EXTERNAL SHIFT MECHANISM
Primary drive cover | Clutch release mechanism | Primary chain adjuster | Primary drive/clutch | Clutch cable | Shift lever assembly | Shift shaft | Specifications

CHAPTER SEVEN: TRANSMISSION AND INTERNAL SHIFT MECHANISM
Internal gearshift mechanism | Transmission | Mainshaft (2004-2005 models) | Countershaft (2004-2005 models) | Transmission (2006-on models) | Mainshaft (2006-on models) | Countershaft (2006-on models) | Main drive gear | Crankcase bearing | Transmission drive sprocket | Specifications

CHAPTER EIGHT: FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Air filter backplate | Carburetor | Intake manifold | Fuel hose and clamps | Throttle and idle cables | Starting enrichment valve (choke) cable replacement | Fuel tank | Fuel shutoff valve | Exhaust system | Evaporative emission control system (California models) | Specifications

CHAPTER NINE: ELECTRICAL SYSTEM
Electrical component replacement | Battery | Charging system | Alternator | Ignition system | Starter | Starter solenoid | Lighting system | Switches | Horn | Starter relay switch | Speedometer | Tachometer | Vehicle speed sensor | Turn signal module (TSM) and turn signal security module (TSSM) | Security system | Fuses | Maxi-fuse | Electrical connectors | Specifications

CHAPTER TEN: WHEELS, TIRES AND DRIVE BELT
Motorcycle stands | Front wheel | Rear wheel | Front and rear hubs | Driven sprocket assembly | Drive sprocket | Drive belt | Wheel inspection | Laced wheels | Disc and cast wheels | Wheel balance | Tires | Specifications

CHAPTER ELEVEN: FRONT SUSPENSION AND STEERING
Handlebar | Front fork | Steering head and stem | Steering head bearing race | Steering play adjustment | Specifications

CHAPTER TWELVE: REAR SUSPENSION
Shock absorbers | Swing arm | Specifications

CHAPTER THIRTEEN: BRAKES
Brake fluid type | Brake service | Front brake pads | Front brake caliper | Front brake master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake hose and line replacement | Brake disc | Rear brake pedal | Brake bleeding | Brake fluid draining and flushing | Specifications

CHAPTER FOURTEEN: BODY
Seat | Front fender | Rear fender | Left side cover | Right side cover | Footrests | Footrest brackets | Sidestand | Fork lock | Specifications

CHAPTER FIFTEEN: SUPPLEMENT
Engine Starting | Engine performance | Starting system | Charging system | Ignition system | Electronic diagnostic system | Fuel system | Brakes | Periodic maintenance | Cylinder head | Engine | Gearcase cover and timing gears | Shift lever assembly | Primary drive/clutch | Air filter backplate | Electronic fuel injection (EFI) | Depressurizing the fuel system | Induction module | Fuel injectors | Throttle position sensor | TMAP sensor | Idle air control (IAC) | Oxygen (O2) sensor | Throttle body | Intake manifold | Fuel tank | Fuel pump module | Throttle and idle cables | Fuel pressure test | Evaporative emission control system (California models) | Exhaust system | Electrical Component Replacement | Battery | Charging system | Alternator | Ignition system | Electronic control module (ECM) | Engine temperature (ET) sensor | Lighting system | Security system | Hands-free security module (HFSM) | HFSM antenna | Fuel level sender resistor | Speedometer | Vehicle speed sensor (VSS) | Clutch switch | Side stand sensor | Wire harness caddy | Relays | Fuses | Electrical connector service | Front wheel | Rear wheel | Handlebar | Front forks | Brake fluid | Front brake master cylinder | Rear brake pedal | Rear fender

INDEX

COLOR WIRING DIAGRAM


Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Harley-Davidson Sportster XL883, XL1200 Repair Manual 2004-2009