Harley-Davidson Sportster XL883, XL1200 2004 - 2013

Clymer Owners Service & Repair Manual

2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013

by Mitzi McCarthy Mike Morlan

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Harley-Davidson Sportster XL883, XL1200 2004 - 2013 - Front Cover

Front Cover

Front Cover

description

Harley-Davidson Sportster XL883, XL1200 2004 - 2013 Clymer Owners Service & Repair Manual covers the following models:
● Sportster XL833 (2004-2009)
● XL883C Custom (2004-2010)
● XL883L Super Low (2004-2013)
● XL883N Iron (2009-2013)
● XL883R Roadster (2004-2013)
● XL1200C Custom (2004-2013)
● XL1200L Super Low (2004-2011)
● XL1200N Nightster (2007-2012)
● XL1200R Roadster (2004-2009)
● XL1200V 72 (2010-2013)
● Sportster XL1200X 48 (2010-2013)

Note: this manual DOES NOT include XR1200

Contents:
AMENDMENT
On the 2/1 edition, page X (QRD) and page 538 have been changed to note the engine oil capacity on:
● 2008 - 2009 models is 2.8 qt (2.65 litre)
● 2004 - 2007 models the capacity is 3.6 qt. (3.4 litre)

QUICK REFERENCE DATA

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

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

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

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

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

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

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

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

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

WHEELS, TYRES 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 / Tyres / Specifications

FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearing race / Steering play adjustment / Specifications

REAR SUSPENSION
Shock absorbers / Swing arm / Specifications

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

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

COLOUR WIRING DIAGRAMS

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.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599696428 (1-599-69642-8)
  • ISBN-13: 9781599696423 (978-1-599-69642-3)
  • Format: Softcover, 616 pages
  • Date Published: 2009

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