Harley Davidson 2005 Sportster Models. Parts catalog — page 1

99451-05А

GENERAL INFORMATION
THIS IS NOT AN ASSEMBLY MANUAL AND SHOULD NOT BE USED AS SUCH.
This Parts Catalog has been prepared for your convenience when ordering parts for the 2005 XL EVOLUTION SPORTSTER models. A complete Hardware Listing is featured at the end of the book. Index numbers shown in the illustrations correspond to index numbers in parts lists. Consult the illustrations when ordering parts so you are sure to get the part required. The number in parenthesis following description of parts is the quantity needed for complete assembly. If there is no number in parenthesis, only one is used. Prices of parts in this catalog are published separately.

The following instructions should be followed carefully when ordering parts.

• The model usage column has a two character code, corresponding to the V.I.N. Model Designation. If the part fits all models “All” will be in the model usage column. The Sportster models are listed at the bottom of each right hand page.

• Specify the correct part number for each item. Check the “MODEL” column of the parts list which shows the model on which the part fits. Whenever in doubt, refer to the Vehicle Identification Number (V.I.N.).

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

See Figure 1. The full 17 digit serial, or Vehicle Identification Number (V.I.N.) is stamped on the right side of the steering head and on a label located on the right side down tube.

An abbreviated V.I.N. is stamped on the left side crankcase at the base between the cylinders.

Sample V.I.N. as it appears on the steering head - 1HD1CGP135K123456 Sample abbreviated V.I.N. as it appears on the left crankcase - CGP5123456

NOTE

Always give the full 17 digit Vehicle Identification Number when ordering parts or making any inquiry about your motorcycle.

Harley-Davidson 2005 Sportster Model V.I.N. Description

ITEM	DESCRIPTION	POSSIBLE VALUES
1	Market destination	1=Domestic 5=lnternational
2	Manufacturer	HD=Harley-Davidson
3	Motorcycle type	1=Heavyweight motorcycle, 4=Middleweight motorcycle
4	Model	see model V.I.N. table
5	Engine type	M=883 cc P=1200 cc
6	Introduction date	1=Regular 4=Special Edition 2=Mid-year 5=Special Edition Cal. Only 3=California
7	VIN check digit	Can be 0-9 or X
8	Model year	5=2005
9	Assembly plant	K=Kansas City, MO.
10	Sequential number (last 6 digits)	varies

2005 Sportster Model V.I.N. Codes

CODE MODEL NAME
CA XL883
CJ XL883C Custom
CM XL883L
CK XL883R
CG XL1200C Custom
CL XL1200R Roadster

• Orders may be placed via your computer for all parts. Please review your system documentation for details on placing orders electronically. All non-warranty replacement crankcase orders require return of the complete left crankcase half wjth VIN. All non-warranty replacement frame orders require return of the steering neck with VIN. Non-compliance will result in a fine. See non-warranty frame and crankcase policy or contact your SPOC team for details.

• To the best knowledge of Harley-Davidson, Inc., the material contained herein is accurate as of the date this publication was approved for printing. Harley-Davidson, Inc. reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation.

ALPHABETICAL INDEX
DESCRIPTION PAGE

Access Door, transmission. . . . . . . . . ..17

Air Cleaner. . . . . . . . . . . . . . . ...27

Air Filter. . . . . . . . . . . . . . . . ...27

Alternator. . . . . . . . . . . . . . . . 29

Axle, front. . . . . . . . . . . . . . . 61,63

Axle, rear. . . . . . . . . . . . . . . 65,67

Battery. . . . . . . . . . . . . . . . 93,95

Battery Cables. . . . . . . . . . . . . . .95

Battery, tray, covers, side & top. . . . . . . . 95

Belt, rear. . . . . . . . . . . . . . . . ..43

Belt Guard. . . . . . . . . . . . . . . . 87

Bracket, choke-883,883L,883C,883R,1200R. . .7,9

Bracket, speedometer-883,883L.883C, 1200R. ...103

Bracket, speedometer-883C,1200C. . . . . ...105

Bracket/Clip, turn signal canceller. . . . . . . 95

Brake Caliper, front. . . . . . . . . . . . ..57

Brake Caliper, rear. . . . . . . . . . . . ...59

Brake Control, front. . . . . . . . . . . . ..49

Brake Control, rear-883,883L,883R,1200R. . . .53

Brake Control, rear-883C,1200C. . . . . . . .55

Brake Disc, front. . . . . . . . . . . . .61,63

Brake Disc, rear. . . . . . . . . . . . ..65,67

Brake line, front. . . . . . . . . . . . . . 49

Brake line, rear. . . . . . . . . . . . . . .51

Cam Gears. . . . . . . . . . . . . . . ..19

Cam Bushings. . . . . . . . . . . . . . .19

Carburetor. . . . . . . . . . . . . . ...23,25

Cable, clutch control. . . . . . . . . . . . 47

Canister, evaporative exhaust. . . . . . . . 121

Chain, primary. . . . . . . . . . . . . . .43

Choke Bracket-883,883L,883C,883R,1200R. . ..7,9

Choke Bracket-1200C. . . . . . . . . . . 111

Circuit Breakers/Fuses. . . . . . . . . . ...117

Clamps, handlebar upper & lower-883,883L,

883R.1200R. . . . . . . . . . . . . . . .81

Clamps, handlebar upper & lower-883C,1200C. ..83

Clutch. . . . . . . . . . . . . . . . . ...41

Clutch Control. . . . . . . . . . . . . . ..47

Coil, ignition. . . . . . . . . . . . . . . .31

Connecting Rods and Bearings. . . . . . . ...13

Cover, oil tank. . . . . . . . . . . . . . ..75

Covers, rocker arm. . . . . . . . . . . . ..11

Crankcase. . . . . . . . . . . . . . . . 15

Cylinders, engine. . . . . . . . . . . . . 7,9

Cylinder Heads. . . . . . . . . . . . . ...7,9

Debris Deflector. . . . . . . . . . . . . ...87

Decals, fuel tank. . . . . . . . . . . . . ..91

Engine. . . . . . . . . . . . . . . . . . 9

Engine mounts, front. . . . . . . . . . . . 45

Enrichener Cable. . . . . . . . . . . . . .27
DESCRIPTION PAGE

Evaporative Emissions Kit. . . . . . . . . ..121

Exhaust System. . . . . . . . . . . . . .101

Fender, front. . . . . . . . . . . . . . . .85

Fender, rear. . . . . . . . . . . . . . . .87

Filter, Air. . . . . . . . . . . . . . . . ...27

Filter, Engine Oil. . . . . . . . . . . . . ...93

Filter, Fuel. . . . . . . . . . . . . . . . 89

Flywheels. . . . . . . . . . . . . . . . .13

Footrests. . . . . . . . . . . . ...39,53,55,79

Fork, front. . . . . . . . . . . . . . . . .71

Fork, rear. . . . . . . . . . . . . . . . .75

Frame. . . . . . . . . . . . . . . . . ...75

Fuel Lines. . . . . . . . . . . . . . . . 89

Fuel Tank. . . . . . . . . . . . . . . . ..89

Fuel Valve. . . . . . . . . . . . . . . . .89

Gasket Kits. . . . . . . . . . . . . . . ..7,9

Gearcase. . . . . . . . . ,. . . . . . . 19

Handlebar-883,883L.883R, 1200R. . . . . . ...81

Handlebar-883C,1200C. . . . . . . . . . ...83

Hardware Listing. . . . . . . . . . . 122-123

Headlamp-883,883L,883R,1200R. . . . . . ...97

Headlamp-883C,1200C. . . . . . . . . . ...99

Housing, speedometer-883,883L,883R,1200R. .103

Housing, speedometer-883C,1200C. . . . . ..105

Horn. . . . . . . . . . . . . . . . . ...111

Ignition Coil. . . . . . . . . . . . . . . ..31

Ignition Module. . . . . . . . . . . . . . .31

Ignition Switch. . . . . . . . . . . . .113,117

Indicator Lamps-883,883L,883R, 1200R. . . . 103

Indicator Lamps-883C,1200C. . . . . . . . 105

Interconnect, exhaust. . . . . . . . . . . .101

Inspection Cover. . . . . . . . . . . . . ..17

Intake Manifold. . . . . . . . . . . . . 23,25

Jet, oil. . . . . . . . . . . . . . . . . ...15

Jiffy Stand. . . . . . . . . . . . . . . . 75

Lever, Clutch Control. . . . . . . . . . . . 47

Lever, Front Brake Control. . . . . . . . . ...49

Lever, Rear Brake Control-883,883L,

883R.1200R. . . . . . . . . . . . . . . .53

Lever, Rear Brake Control-883C,1200C. . . . ..55

Lever, Transmission Gear Shift-883,883L,

883R.1200R. . . . . . . . . . . . . . . .37

Lever, Transmission Gear Shift-883C,1200C. . ...39

License Plate Bracket. . . . . . . . . . . ..87

MAP Sensor. . . . . . . . . . . . . . 23,25

Master Cylinder, front. . . . . . . . . . . ...49

Master Cylinder, rear. . . . . . . . . . . . 51

Mirrors-883,883L,883R, 1200R. . . . . . . . 97

Mirrors-883C,1200C. . . . . . . . . . . . .99

Module, ignition. . . . . . . . . . . . . . 31

DESCRIPTION PAGE

Module, security system/turn signal canceller. ...117

Mounts, engine. . . . . . . . . . . . . . 45

Mufflers. . . . . . . . . . . . . . . . ..101

Numerical Index. . . . . . . . . . . .124-128

Oil Filter. . . . . . . . . . . . . . . . ...93

Oil Jet. . . . . . . . . . . . . . . . . ...15

Oil Pressure Switch. . . . . . . . . . . ...115

Oil Pump. . . . . . . . . . . . . . . . ..21

Oil Pump Drive Gear. . . . . . . . . . . . 19

Oil Tank. . . . . . . . . . . . . . . . . 93

Oil Tank Cover. . . . . . . . . . . . . . ..75

Pistons and Piston Rings. . . . . . . . . ..9,13

Primary Cover. . . . . . . . . . . . . . ..17

Push Rods & Covers. . . . . . . . . . . . 11

Regulator. . . . . . . . . . . . . . . . .29

Relay, starter. . . . . . . . . . . . . . ..117

Rims, front & rear. . . . . . . . . ..61,63,65,67

Rocker Arms & Covers. . . . . . . . . . . 11

Seats. . . . . . . . . . . . . . . . . . 77

Sensor, MAP. . . . . . . . . . . . . ...23,25

Sensor, speed-883,883L,883R,1200R. . . . ..103

Sensor, speed-883C,1200C. . . . . . . . ...105

Shifter-883,883L.883R, 1200R. . . . . . . . .37

Shifter-883C, 1200C. . . . . . . . . . . . .39

Shock Absorbers. . . . . . . . . . . . . .73

Side Cover, module. . . . . . . . . . . . ..73

Spark Plugs. . . . . . . . . . . . . . . .31

Speedometer-883,883L,883R,1200R. . . . . 103

Speedometer-883C, 1200C. . . . . . . . . 105

Speed Sensor-883,883L,883R,1200R. . . . ...103

Speed Sensor-883C,1200C. . . . . . . . ...105

Sprocket Cover, transmission. . . . . . . . ..43

Sprockets. . . . . . . . . . . . . ...43,63,65

Starter Motor. . . . . . . . . . . . . . . 33

Stator. . . . . . . . . . . . . . . . . ...29

Steering Head Brackets, upper & lower. . . . ...69

Swing Arm. . . . . . . . . . . . . . . ...75

Switches. . . . . . . . . . . . . . . ..117

Switches, handlebar. . . . . . . . . . . ..119

Switches, ignition. . . . . . . . . . . 113,117

Switches, starter. . . . . . . . . . . . . 119

Tachometer-883,883L.883R, 1200R. . . . . ...103

Tail Lamp. . . . . . . . . . . . . . . ...109

Tappets. . . . . . . . . . . . . . . . . 11

Throttle Control-883,883L.883R, 1200R. . . . ...81

Throttle Control-883C, 1200C. . . . . . . . ...83

Transmission Gears. . . . . . . . . . . . .35

Turn Signal Canceller. . . . . . . . . . . .117

Turn Signals. . . . . . . . . . . . . . ...107

Valves & Guides. . . . . . . . . . . . . . .9
PAGE

Voltage Regulator. . . . . . . . . . . . . 29

Wheels, front - cast. . . . . . . . . . . . ..61

Wheels, front - laced. . . . . . . . . . . . 63

Wheels, rear - cast. . . . . . . . . . . . ...65

Wheels, rear - laced. . . . . . . . . . . . .67

Wiring Harness, main. . . . . . . . . .113,115