Positioning:
The Harley-Davidson XL1200C Sportster Custom from the 2004-2006 era represents a classic cruiser model that blended iconic Harley styling with a more accessible platform, appealing to a wide range of riders seeking customization potential and the distinct Sportster character.
Competition:
Competed against other V-twin cruisers from brands like Indian, Victory, and Japanese manufacturers offering similar displacement and cruiser aesthetics, such as Yamaha V-Star series, Honda Shadow series, and Suzuki Boulevard series.
Features:
Key features include the robust Evolution 1200cc V-twin engine, comfortable riding position, distinctive Sportster chassis, ample chrome detailing, and a platform ripe for personalization through a vast aftermarket accessory catalog.
Engine:
Complete engine disassembly, inspection, repair, and assembly of the Evolution V-Twin engine.
Transmission:
Service and repair of the 5-speed constant mesh transmission and clutch assembly.
Fuel System:
Carburetor (Keihin CV) tuning, cleaning, and overhaul; fuel injection system diagnosis and repair (if applicable for specific sub-models within the years).
Electrical System:
Wiring diagrams, ignition system, charging system (alternator, regulator/rectifier), lighting, instrumentation, and starting system.
Chassis And Suspension:
Front forks (telescopic), rear shock absorbers, swingarm, frame inspection and repair, wheel bearing service.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures.
Bodywork And Trim:
Fender removal and installation, fuel tank service, seat assembly, handlebar replacement, and other cosmetic components.
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement, battery maintenance.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Repair:
Step-by-step repair instructions for all major components and systems.
Overhaul:
Detailed instructions for complete engine and transmission overhauls.
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and advanced diagnostics.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1200cc (73.4 cubic inches)
Bore X Stroke:
3.498 in. x 4.25 in. (88.9 mm x 108 mm)
Valve Train:
Overhead valve (OHV) with two valves per cylinder
Camshafts:
Single camshaft, chain-driven (specific cam profile numbers typically found in service manual)
Horsepower Est:
Approximately 65-70 HP at 5500 RPM (specific dyno figures vary)
Torque Est:
Approximately 70-75 ft-lbs at 3500 RPM (specific dyno figures vary)
Fuel Delivery:
Keihin 40mm CV (Constant Velocity) carburetor
Fuel Tank Capacity:
3.1 gallons (11.7 L)
Oil Capacity:
Approximately 3 quarts (2.8 L) with filter change
Oil Type Spec:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50 Motorcycle Oil or equivalent API SG certified oil.
Transmission Type:
5-speed, constant mesh
Clutch Type:
Multi-plate, wet-type, cable-actuated
Optional Transmissions:
N/A for this model year and variant.
Gear Ratios:
Gear ratios are specific and detailed within the manual; essential for performance tuning and diagnostics.
Transmission Fluid:
Harley-Davidson Transmission and Primary Chaincase Lubricant (Formula+ recommended) or equivalent.
Length:
Approx. 90.1 inches (2289 mm)
Width:
Approx. 34.1 inches (866 mm)
Height:
Approx. 47.2 inches (1199 mm)
Seat Height Unladen:
Approx. 27.1 inches (688 mm)
Ground Clearance:
Approx. 4.25 inches (108 mm)
Dry Weight Est:
Approx. 519 lbs (235.4 kg)
Gross Vehicle Weight Rating Gvwr:
Typically around 950 lbs (431 kg); check VIN plate for exact figure.
Payload Capacity:
Calculated based on GVWR and dry weight.
Wheelbase:
Approx. 60.0 inches (1524 mm)
Safety Ratings:
Motorcycles are not typically rated by organizations like NHTSA in the same way as cars. Safety is primarily dependent on rider skill and adherence to maintenance.
Active Safety:
Disc brakes front and rear for stopping power. Rider skill is the primary active safety feature.
Passive Safety:
Frame integrity, rider aids like proper tire inflation and brake maintenance are crucial.
Recalls:
Specific recalls for these model years would be documented by Harley-Davidson and available through VIN lookup services. The manual will detail maintenance that can prevent issues related to known recalls.
Infotainment System:
Typically basic instrumentation: speedometer, tachometer (optional), odometer, trip meter, and indicator lights. No integrated infotainment systems beyond basic functionality.
Driver Assistance:
N/A for this model year; driver assistance features were not standard on motorcycles of this era.
Lighting System:
Halogen headlight, LED tail light, incandescent turn signals. Bulb types and replacement procedures are detailed in the manual.
Initial Service:
First service typically around 1,000 miles (1600 km), including oil change, filter change, and chassis inspection.
Routine Maintenance:
Subsequent services generally every 5,000 miles (8,000 km) or annually, covering oil changes, brake checks, chain lubrication and adjustment, tire pressure checks, and general inspection. More in-depth checks occur at higher mileage intervals.
Engine Oil:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50 Motorcycle Oil or equivalent SAE 20W-50 API SG/SH/SJ certified.
Primary Chaincase Oil:
Harley-Davidson Formula+ or equivalent manual transmission fluid (check manual for specific viscosity).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specific fork oil viscosity (e.g., 10W) and volume will be detailed in the manual for front fork service.
Common Wear Items:
Brake pads, clutch plates, tires, fork seals, and drive belt are common wear items requiring regular inspection and replacement. Carburetor adjustments may be needed over time.
Potential Issues:
Some models of this era may experience clutch cable adjustment requirements, minor oil seepage, or carburetor tuning needs due to ethanol in fuel. The manual provides solutions for these.
Oil Filter:
Commonly uses Harley-Davidson part number 63796-77A or equivalent aftermarket filters (e.g., K&N KN-170, Willie's HD201).
Air Filter:
Specific part number varies by original equipment and aftermarket upgrades; the manual will detail the OE type and replacement procedures.
Brand History:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, classic styling, and strong rider community. The Sportster line, introduced in 1957, is one of its longest-running and most versatile platforms.
Sportster Evolution:
The XL1200C Sportster Custom represents a significant step in the Sportster line's evolution, particularly with the adoption of the larger 1200cc Evolution engine, offering increased power and torque over earlier models. The 'Custom' designation highlights its styling cues and predisposition for personalization.
Manufacturing Location:
Harley-Davidson motorcycles of this era were primarily manufactured in the United States.
Key Design Changes 04-06:
These years saw refinements to the Evolution engine, chassis, and electrical systems. Notably, 2004 models often featured rubber-mounted engines for improved vibration isolation compared to earlier rigid-mount Sportsters.
Model Awards:
While specific awards for the 2004-2006 XL1200C model are not widely publicized, the Sportster line has consistently been recognized for its enduring style, customization potential, and contribution to motorcycle culture. It's a staple in the cruiser segment.
Consumer Ratings:
Owners generally rate the XL1200C highly for its ride quality, distinctive character, and Harley-Davidson's brand appeal. The manual empowers owners to maintain these positive attributes.
