Harley Davidson XL1200C Sportster Custom 2004 Manual

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Year: 2004 Engine Type: Air-cooled, Evolution V-twin Chassis Code: XL 👋 Introduction Market Position Category: Cruiser Motorcycle Target Audience: Owners...

24 people are viewing this right now

Type: Motorcycle

Vendor:

Sku: 419190

Tags: 2004 Harley Davidson Misc Motorcycle Motorcycles XL1200C Sportster Custom

Product variants

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XL1200C Sportster Custom

Year:

Engine Type:

Air-cooled, Evolution V-twin

Chassis Code:

👋 Introduction

Market Position

Category:

Cruiser Motorcycle

Target Audience:

Owners and technicians seeking detailed repair and maintenance information for the 2004 Harley-Davidson XL1200C Sportster Custom.

Competitive Analysis

Positioning:

The XL1200C Sportster Custom represents Harley-Davidson's classic cruiser offering, known for its iconic styling, V-twin rumble, and customizability. This manual is essential for maintaining its performance and longevity.

Key Features

Vehicle Focus:

Emphasis on the Sportster platform's blend of classic Harley-Davidson heritage with modern touring and custom capabilities for its era.

Manual Value

Value Proposition:

Provides the same official, in-depth information used by Harley-Davidson dealerships, empowering owners to perform maintenance and repairs confidently and correctly.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete factory service repair

Page Count

Pages:

Hundreds (estimated 400-600 based on typical Harley service manuals)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Download PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, overhaul, timing, valve train, cylinder heads, pistons, connecting rods, crankshaft, lubrication system, cooling system (air).

Fuel System:

Carburetor (Keihin CV), fuel tank, fuel lines, fuel pump, fuel filter, emissions control.

Ignition System:

Ignition module, ignition coil, spark plugs, wiring.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, gauges, switches, relays, fuses, wiring diagrams.

Transmission Drivetrain:

Clutch operation and adjustment, primary drive, transmission case, gear sets, shift mechanism, final belt drive, belt tension.

Brakes:

Front and rear brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures.

Suspension:

Front fork (telescopic, cartridge type), rear shock absorbers, fork oil change, fork seal replacement, rear suspension adjustment.

Wheels Tires:

Wheel bearing inspection and replacement, tire selection and installation, tube vs. tubeless considerations, spoke tension (if applicable).

Steering Frame:

Headset bearings, steering stem, frame components, triple clamps.

Bodywork:

Fenders, fuel tank, seat, handlebars, controls, electrical panel access, cosmetic component removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, brake fluid flush, chain/belt adjustment, lubrication points.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and brake issues.

Repair Overhaul:

Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.

Diagnostics:

Identification of fault codes (if applicable for the era), symptom-based diagnostics.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for both independent technicians and advanced DIY enthusiasts. Includes torque specifications, clearances, and critical assembly procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Printable.

Binding Type

Binding:

N/A (Downloadable PDF - intended for digital use or user printing/binding)

Paper Type

Paper:

N/A (Digital format)

Searchability

Search Functionality:

Typically searchable PDF, allowing quick access to specific topics.

⚙️ Engine Specifications

Primary Engine

Engine Name:

Evolution V-twin (1200cc)

Displacement:

1200 cc (73.4 cubic inches)

Bore X Stroke:

3.50 in. x 3.81 in. (88.9 mm x 96.8 mm)

Compression Ratio:

9.0:1

Performance

Horsepower Est:

Approx. 60-65 HP (as per typical 1200 Evolution engines of this era, official figures may vary)

Torque Est:

Approx. 68-72 ft-lbs @ 3200 RPM (as per typical 1200 Evolution engines of this era, official figures may vary)

Fuel System

Fuel Delivery:

Keihin CV 40mm Carburetor

Fuel Type:

Unleaded gasoline, minimum 89 octane (Octane Rating is typically RON+MON/2, check manual for specific Harley recommendation)

Lubrication System

Oil Capacity W Filter:

3.0 US qt (2.8 L) - Verify with manual for exact capacity

Oil Type:

Harley-Davidson Genuine V-Twin Oil (or equivalent API CG-4 or higher SAE 20W50)

Cooling System

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Type:

5-speed Constant Mesh

Gear Ratios:

1st: 9.315, 2nd: 6.723, 3rd: 4.704, 4th: 3.704, 5th: 3.225 (Typical values for this transmission, confirm with manual)

Primary Drive:

45-tooth, 2.06:1 ratio, enclosed in primary chaincase

Final Drive:

32-tooth, 3.00:1 ratio, belt drive

Features

Clutch Type:

Wet, multi-plate

Transmission Fluid Type:

Harley-Davidson Formula+, SAE 80W-90 Hypoid Gear Oil (check manual for exact specification)

📐 Dimensions

Exterior

Length Overall:

90.5 in. (2299 mm)

Wheelbase:

60.0 in. (1524 mm)

Ground Clearance:

4.5 in. (114 mm)

Seat Height Laden:

26.5 in. (673 mm)

Weights

Dry Weight:

552 lbs (250 kg)

Gross Vehicle Weight Rating Gvwr:

937 lbs (425 kg)

Payload Capacity:

Approx. 385 lbs (175 kg)

🛡️ Safety Features

Ratings

Crash Test Rating:

N/A (Motorcycles typically do not undergo standardized crash testing like automobiles; focus is on operational safety features.)

Active Features

Braking System:

Dual-piston front caliper with 292mm disc, dual-piston rear caliper with 292mm disc.

Lighting:

Halogen headlight, LED tail/stop light, incandescent front and rear turn signals.

Passive Features

Frame Construction:

Mild steel, high-tensile strength tubing, cradle frame.

💡 Technology Features

Infotainment

Display Type:

Analog speedometer with integrated odometer and trip meter. Smaller analog tachometer (often optional or part of a handlebar clamp assembly).

Audio System:

None standard. Aftermarket audio systems were common additions.

Driver Assistance

Not available on the 2004 XL1200C Sportster Custom.

Connectivity

Bluetooth Usb:

Not available. This era predates widespread integrated consumer electronics connectivity in motorcycles.

Ignition Features

Key Type:

Ignition key and fork lock with integrated starter button on handlebar. Security system (H-D Smart Security System) may be an optional dealer-installed feature.

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first (includes oil change, primary chain inspection, etc.)

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months for regular maintenance (oil, filter, lubrication, inspection). Refer to manual for detailed schedule.

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin Oil SAE 20W50 (or equivalent)

Primary Chain Case Fluid:

Harley-Davidson Formula+, SAE 80W-90 Hypoid Gear Oil (or equivalent)

Transmission Fluid:

Harley-Davidson Formula+, SAE 80W-90 Hypoid Gear Oil (or equivalent)

Brake Fluid:

DOT 4 (Harley-Davidson Brake Fluid recommended)

Fork Oil:

Harley-Davidson Type E Fork Oil (or equivalent SAE 10W, verify viscosity with manual)

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, exhaust gaskets, drive belt wear.

Electrical Components:

Potential issues with voltage regulators and stators on earlier Evolution models, though improvements were made over the years. Always verify with manual diagnostics.

Carburetor Tuning:

CV carburetor can require periodic adjustment for optimal performance and idle stability, especially with altitude or temperature changes.

📚 Vehicle History

Brand Heritage

Brand Founding:

Founded in 1903, Milwaukee, Wisconsin, USA.

Sportster Legacy:

The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model line, evolving from a lightweight sport bike to the iconic cruiser it is today.

Model Evolution

Xl Platform:

The XL1200C Sportster Custom variant introduced significant custom styling cues, often including a larger front wheel (e.g., 19-inch) and a distinctive fuel tank.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA (for 2004 models)

🏆 Awards & Recognition

Recognitions

Historical Significance:

The Sportster model line is a recognized icon in American motorcycling culture, often lauded for its classic styling and robust V-twin performance.