Harley-Davidson Sportster 883 / 1200 (rubber mount, EFI) — Example photo: order_242 from Chile, CC BY-SA 2.0, Wikimedia Commons

Have this bike? Send a photo or the manual's service chart

Harley-Davidson · Harley-Davidson Evolution Sportster (1986-2021)

Sportster 883 / 1200 (rubber mount, EFI)

Library entry covers 2004-2021

39 factory 32 guideline

Published source

2006 HD Buell Service Intervals (H-D factory service interval tables 43-47)

Factory workshop manual. Covers 2006.

71 items for a 2006 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Hydraulic lifters (no routine clearance adjustment)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Air / oil cooled
Primary drive: Chain in oil-bath case with its own oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2006 Harley-Davidson Sportster 883 / 1200 (rubber mount, EFI)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 3,000 mi or 12 months

6 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 5,000 mi

22 items

Change engine oil

Engine

Factory

Manual: Replace engine oil and filter. Factory: marked at every column: 1000 mi then every 5000 mi
Electrical equipment and switches: Check operation

Engine

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Engine idle speed: Check adjustment

Engine

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Rear master cylinder outer boot: inspect

Engine

Factory

Factory: every 5000 mi (8000 km) from 5000 mi; replace every four years (note 2) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Replace oil filter

Engine

Factory

Manual: Replace engine oil and filter. Factory: filter changed with oil, 1000 then every 5000 mi
Road test: verify component and system functions

Engine

Factory

Factory: first at 1000 mi (1600 km), then every 5000 mi (8000 km) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Verify component and system functions

Engine

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Clean / inspect air filter

Fuel and air

Factory

Manual: Inspect air cleaner, service as required. Factory: every interval (1000, then each 5000)
Fuel valve, lines and fittings: Inspect for leaks

Fuel and air

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Check/adjust clutch. Factory: every interval
Check / adjust primary chain

Primary and gearbox

Factory

Manual: Check primary chain adjustment. Factory: every interval
Inspect drive belt, pulleys and tension

Final drive

Factory

Manual: Check rear belt. Factory: every interval
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Inspect shock absorbers. Factory: every interval
Brake caliper boots and bushings: inspect

Brakes

Factory

Factory: every 5000 mi (8000 km) from 5000 to 20000 mi; replace at 25000 mi or every four years (note 2) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Brake caliper pins: inspect

Brakes

Factory

Factory: every 5000 mi (8000 km) from 5000 to 20000 mi; lubricate at 25000 mi; dealer item Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Brake fluid: Check levels and condition

Brakes

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Check brake pads and discs

Brakes

Factory

Manual: Inspect brake pads and discs for wear. Factory: every interval
Front brake lever pin: inspect

Brakes

Factory

Factory: every 5000 mi (8000 km) from 5000 to 20000 mi; lubricate at 25000 mi; dealer item Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Oil lines and brake system: Inspect for leaks

Brakes

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Throttle, brake, enrichener and clutch controls: Check, adjust and lubricate

Brakes

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Check tire pressure, inspect tread. Factory: every interval
Wheel spokes: Check tightness

Wheels and tires

Factory

Factory: As printed: X in all six columns (1,000 / 5,000 / 10,000 / 15,000 / 20,000 / 25,000 mi) Notes 1, 4: Not all vehicles are equipped with spoke wheels.

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 12 months

1 item

Change primary chaincase oil

Primary and gearbox

Guideline

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi

7 items

Critical fasteners: check tightness

Engine

Factory

Factory: first at 1000 mi (1600 km), then 10000 and 20000 mi; dealer item (note 1) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Engine mounts and stabilizer links: inspect

Engine

Factory

Factory: marked at 10000 and 20000 mi (16000, 32000 km); dealer item (note 1) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Spark plugs: inspect

Engine

Factory

Factory: marked at 1000, 5000, 15000 and 25000 mi, between replacements Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Spark plugs: replace

Engine

Factory

Factory: marked at 10000 and 20000 mi (16000, 32000 km) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Transmission lubricant: replace

Primary and gearbox

Factory

Factory: first at 1000 mi (1600 km), then 10000 and 20000 mi Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Steering head bearings: lubricate

Front end

Factory

Factory: marked at 10000 and 20000 mi (16000, 32000 km); dealer item Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)
Jiffy stand: inspect and lubricate

Rear suspension and frame

Factory

Factory: first at 1000 mi (1600 km), then 10000 and 20000 mi; dealer item (note 1) Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)

Every 12,000 mi or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 20,000 mi

1 item

Steering head bearings: adjust

Front end

Factory

Factory: first at 1000 mi (1600 km), then 20000 mi (32000 km); dealer item Read from Harley-Davidson/Buell 2006 Service Intervals, Table 43 (2006 Sportster models)

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,000 mi

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Factory

Manual: Replace rear fork bearings. Factory: every 30,000 mi

Every 50,000 mi

1 item

Replace drive belt (wear or damage based)

Final drive

Guideline

Every 12 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Factory

Manual: Check battery and clean connections. Factory: annually

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Replace brake rubber components in master cylinders and calipers. Factory: every four years

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

6 items

Fuel tank filter screen: Clean

Fuel and air

Factory

Factory: As printed: X in one column only; columns not readable
Front fork oil: Replace

Front end

Factory

Factory: As printed: X in one column only; columns not readable
Brake caliper boots and bushings: Replace

Brakes

Factory

Factory: As printed: X in one column only; columns not readable Notes 1, 2 (2: Replace every four (4) years.)
Brake caliper pins: Lubricate

Brakes

Factory

Factory: As printed: X in one column only; columns not readable Notes 1, 2 (2: Replace every four (4) years.)
Brake components: Lubricate master cylinder pistons

Brakes

Factory

Factory: As printed: X in one column only; columns not readable Notes 1, 2 (2: Replace every four (4) years.)
Front brake lever pin: Lubricate

Brakes

Factory

Factory: As printed: X in one column only; columns not readable Notes 1, 2 (2: Replace every four (4) years.)

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.