Harley-Davidson Sportster 1200 Roadster maintenance schedule & recalls
2004–2009
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Maintenance schedule
General guidance — based on common manufacturer intervals| Service | Interval |
|---|---|
| Oil & filter | every 4,000 mi or 6 months |
| Chain & sprockets | every 600 mi or 3 months |
| Brakes | every 12 months |
| Valve adjustment | every 16,000 mi or 24 months |
| Battery | every 12 months |
| Spark plugs | every 8,000 mi or 24 months |
| Fluids/coolant | every 24 months |
Recalls
ON CERTAIN MOTORCYCLES, THE FRONT MASTER BRAKE CYLINDER ASSEMBLY HAD BEEN BUILT WITH INADEQUATE LUBRICATION ON THE SECONDARY CUP. THIS COULD CAUSE THE SLIDING RESISTANCE OF THE PISTON TO BE EXCESSIVE, WHICH IN TURN COULD CAUSE THE RETURN OF THE PISTON TO BE SLOW UPON RELEASE OF THE BRAKE.
Remedy: DEALERS WILL REBUILD THE MASTER CYLINDER. THE RECALL BEGAN ON JULY 10, 2006. OWNERS MAY CONTACT HARLEY DAVIDSON AT 1-414-343-4056.
CERTAIN MOTORCYCLES MAY HAVE BEEN PRODUCED WITH DEFECTIVE FUEL SHUT-OFF VALVES. THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.
Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN FEBRUARY 7, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080.
CERTAIN FUEL SHUT-OFF VALVES USED AS REPLACEMENT EQUIPMENT, P/NOS 61338-02, 62169-02A, 61338-94D, AND 62169-95C FOR USE ON CERTAIN 2005 CARBURETED SPORTSTERS, DYNA, SOFTAIL, AND TOURING MODEL MOTORCYCLES. THESE VALVES MAY HAVE BEEN PRODUCED WITH THE FUNCTIONALITY OF THE 'ON' POSITION AND THE 'RESERVE' POSITION OF THE VALVE MAY HAVE BEEN REVERSED.
Remedy: DEALERS WILL INSPECT THE FUEL VALVE AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN JANUARY 27, 2005. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4080. IF YOU HAVE HAD OR INSTALLED A REPLACEMENT FUEL SHUT-OFF VALVE IN YOUR MOTORCYCLE, PLEASE TAKE YOUR VEHICLE TO YOUR DEALER TO HAVE THE VALVE INSPECTED FOR PROPER OPERATION AS SOON AS POSSIBLE.
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Common questions
How often should the oil & filter be serviced on a Harley-Davidson Sportster 1200 Roadster?
Service every 4,000 mi or 6 months for the Harley-Davidson Sportster 1200 Roadster (2004–2009).
How often should the chain & sprockets be serviced on a Harley-Davidson Sportster 1200 Roadster?
Service every 600 mi or 3 months for the Harley-Davidson Sportster 1200 Roadster (2004–2009).
How often should the brakes be serviced on a Harley-Davidson Sportster 1200 Roadster?
Service every 12 months for the Harley-Davidson Sportster 1200 Roadster (2004–2009).
How often should the valve adjustment be serviced on a Harley-Davidson Sportster 1200 Roadster?
Service every 16,000 mi or 24 months for the Harley-Davidson Sportster 1200 Roadster (2004–2009).