Harley-Davidson XL Sportster Service & Repair Manual 2004-2013
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Harley-Davidson XL883-XL1200 Sportster Service and Repair Manual (2004-2013) M427-4
Harley-Davidson XL883, XL883C, XL883L, XL883N, XL883R, XL1200C, XL1200L, XL1200N, XL1200R and XL1200X manual.
Does not include XR1200.
Includes Color Wiring Diagrams.
This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the Harley-Davidson Sportster motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual, making it an indispensable part of your tool box.
Models:
Harley-Davidson Sportster XL833 (2004-2009)
Harley-Davidson Sportster XL883C Custom (2004-2010)
Harley-Davidson Sportster XL883L Super Low (2004-2013)
Harley-Davidson Sportster XL883N Iron (2009-2013)
Harley-Davidson Sportster XL883R Roadster (2004-2013)
Harley-Davidson Sportster XL1200C Custom (2004-2013)
Harley-Davidson Sportster XL1200L Super Low (2004-2011)
Harley-Davidson Sportster XL1200N Nightster (2007-2012)
Harley-Davidson Sportster XL1200R Roadster (2004-2009)
Harley-Davidson Sportster XL1200V 72 (2010-2013)
Harley-Davidson Sportster XL1200X 48 (2010-2013)
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 removal installation / 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
SUPPLEMENT 2007-2013 SERVICE INFORMATION
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 (TP) 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 / Specifications
INDEX
COLOR WIRING DIAGRAMS
With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.
Key features:
- All colour step-by-step guides for over 200 jobs with 700+ photos
- Image zoom feature for close-up view of jobs
- Brand-new “how to” video tutorials covering key repair tasks
- Print complete sections to take with you into the workshop
- Troubleshooting section – quickly find the cause of a problem
- Colour wiring diagrams help track problems quickly and easily
- Easy search feature – find your job fast
- Dictionary of automotive terms
- Quick links to popular DIY tasks and other jobs linked to your task
- Conversion calculator – imperial and metric units
