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

From the Publisher:

This detailed, comprehensive manual covers all 2004-2009 Harley-Davidson Sportster XL models, 883cc and 1200cc.

The expert text gives complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide you through every step. The book includes all you will need to know to keep your Harley Sportster running right. Throughout this book where differences occur among the models, they are clearly identified.

A shop manual is a reference. You want to be able to find information fast. As in all Clymer books, this one is designed with you in mind. All chapters are thumb tabbed. Important items are extensively indexed. All procedures, tables, photos, etc., in this manual are for the reader who may be working on the bike for the first time. All the most frequently used specifications and capacities are summarized in the Quick Reference Data pages at the front of the book.

Keep the book handy in your tool box. It will help you better understand how your bike runs, lower repair costs and generally improve your satisfaction with the motorcycle.

PRODUCT DETAILS:
  • Publisher: Clymer Manuals - 2009
  • Author: Mike Morlan
  • Binding: Paperback - 8.25 x 10.75 inches
  • Pages: 596 - Hundreds of b&w photos and illustrations
  • ISBN: 9781599692876
   
 
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