Market Segment:
Cruiser/Custom Motorcycle
Competitors 2004:
Indian Scout, various Japanese cruisers (e.g., Yamaha Virago, Honda Shadow, Kawasaki Vulcan).
Sportster Identity:
The Sportster line represents Harley-Davidson's entry-level cruiser, known for its distinctive character and customizability.
Manual Value Proposition:
Provides DIY mechanics and owners with the precise information required to maintain and repair their 2004 XLH Sportster, saving time and money on dealership services.
Engine Management:
Detailed diagnostics and repair for ignition, fuel injection, and emissions control.
Drivetrain:
Service and overhaul procedures for the transmission and final drive.
Brake System:
Hydraulic brake system service, including master cylinder, calipers, lines, and bleeding procedures.
Electrical Diagnostics:
Wiring diagrams, component testing, and troubleshooting for lighting, starting, charging, and accessories.
Suspension And Steering:
Fork service, shock absorber replacement, and steering head bearing maintenance.
Cooling System:
Though air-cooled, it covers related components like oil cooler systems.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustments, and lubrication schedules.
Engine Overhaul:
Top-end rebuilds, piston and ring replacement, valve adjustments, and cylinder head service.
Transmission Service:
Clutch adjustment and replacement, gear inspection, and transmission fluid service.
Electrical Repair:
Component replacement (e.g., stator, regulator, starter motor), wiring harness repair, and diagnostic code interpretation.
Chassis Repair:
Frame inspection, suspension component replacement, and wheel bearing service.
Troubleshooting Guides:
Systematic diagnostic steps for common and uncommon performance issues.
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagrams and specifications.
Engine Type:
Evolution V-Twin, Air-Cooled
Displacement:
1200cc (for XLH1200 variant), 883cc (for XLH883 variant)
Bore X Stroke:
XLH1200: 3.50 in x 3.81 in (88.9 mm x 96.8 mm); XLH883: 3.00 in x 3.81 in (76.2 mm x 96.8 mm)
Compression Ratio:
XLH1200: 9.0:1; XLH883: 8.8:1 (approx.)
Horsepower:
XLH1200: Approx. 60-65 HP; XLH883: Approx. 50-55 HP (Figures are estimates and vary)
Torque:
XLH1200: Approx. 67-70 ft-lbs; XLH883: Approx. 55-60 ft-lbs (Figures are estimates and vary)
Fuel Delivery:
Carbureted (Keihin CV Carburetor) or Electronic Sequential Port Fuel Injection (ESPFI) depending on specific model variant.
Fuel Type:
Unleaded Gasoline, 91 Octane (R+M)/2 or higher recommended.
Safety Certification:
Complies with Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.
Braking System:
Dual front disc brakes and single rear disc brake. ABS was generally not standard on Sportsters of this era.
Lighting:
Halogen headlamp, taillight, brake light, and turn signals.
Oil Change Interval:
Every 5,000 miles (8,000 km) or annually. Refer to manual for specific oil type and capacity.
Primary Chain Tension Check:
Every 2,500 miles (4,000 km) or annually.
Spark Plug Replacement:
Every 10,000 miles (16,000 km).
Brake Fluid Flush:
Every 2 years.
Engine Oil Type:
Harley-Davidson V-Twin Synthetic 20W-50 or equivalent meeting Harley-Davidson specifications.
Engine Oil Capacity:
Approx. 3.0 US quarts (2.8 L) with filter change for 1200cc; 2.8 US quarts (2.6 L) for 883cc.
Primary Chain Case Oil Type:
Harley-Davidson Primary Fluid or Formula Plus, or SAE 15W-30 engine oil.
Primary Chain Case Oil Capacity:
Approx. 2.4 US quarts (2.3 L).
Transmission Oil Type:
Harley-Davidson Transmission Lubricant or SAE 85W-140 gear oil.
Transmission Oil Capacity:
Approx. 2.5 US quarts (2.4 L).
Common Wear Items:
Clutch plates, brake pads, wheel bearings, and fork seals are common wear items requiring periodic inspection and replacement.
Electrical Connections:
Corrosion or loosening of electrical connectors can lead to intermittent issues; periodic inspection and dielectric grease application is recommended.
Carburetor Tuning:
CV carburetors may require occasional tuning or cleaning for optimal performance, especially with altitude or aftermarket modifications.
Harley Davidson Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling.
Sportster Lineage:
The Sportster platform has been in continuous production since 1957, evolving through various engine displacements and design iterations. The 2004 model year saw significant chassis updates, including a new frame and suspension.
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin)
