🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Year:

2004

Chassis Code:

XL

👋 Introduction

Market Position:

The Harley-Davidson Sportster line has historically occupied the entry-level to mid-range cruiser segment, appealing to a wide demographic with its iconic styling and accessible performance.

Competitive Analysis:

In 2004, the Sportster competed against models from brands like Triumph (Bonneville), Honda (Shadow series), Yamaha (V-Star), Kawasaki (Vulcan), and Suzuki (Intruder/Boulevard) in the middleweight cruiser market.

Key Features:

The 2004 Sportster models are characterized by their Evolution V-twin engines, classic styling, and a focus on rider engagement and customization potential.

Chassis Design:

The 2004 models feature a split cradle steel frame and a rubber-mounted engine for enhanced rider comfort, a significant upgrade from earlier generations.

📋 Manual Details

Primary Coverage:

Workshop Service Repair

Specific Models Covered:

Likely covers various Sportster 883 and 1200 models from 2004, including but not limited to XL883, XL883C (Custom), XL883R, XL1200C (Custom), XL1200R (Roadster), XL1200S (Sport).

Page Count:

710

Manual Type:

Service Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, lubrication, cooling, fuel and exhaust systems, ignition, starting and charging systems, engine diagnostics, performance tuning.

Transmission Drivetrain:

Transmission assembly, disassembly, maintenance, clutch operation, primary drive, final drive, troubleshooting.

Chassis Suspension Steering:

Frame, front fork, rear suspension, wheels, tires, spokes, steering assembly, bearing maintenance.

Brake Systems:

Front and rear brake systems, hydraulic systems, pad replacement, rotor service, bleeding procedures, troubleshooting.

Electrical Systems:

Wiring diagrams, lighting systems, instrumentation, ignition system components, battery, charging system, starter motor, electrical troubleshooting, diagnostics.

Fuel System:

Carburetor service (Keihin CV 40), fuel tank, fuel lines, fuel pump (if applicable), fuel system diagnostics.

Exhaust System:

Exhaust pipes, mufflers, heat shields, mounting hardware, service and replacement.

Bodywork Fittings:

Fenders, fuel tank, seat, handlebars, controls, mirrors, lighting fixtures, body panel removal and installation.

Frame And Fork:

Frame inspection, repair, and front fork assembly/disassembly.

Preventative Maintenance:

Oil changes, filter replacements, chain adjustment, tire pressure checks, brake inspections, lubrication points.

Troubleshooting:

Diagnostic charts for common problems, electrical system troubleshooting, engine performance issues, starting problems.

Repair Rebuild:

Engine rebuild procedures, transmission overhaul, fork seal replacement, brake caliper overhaul, carburetor rebuilding.

Component Replacement:

Replacement of spark plugs, air filters, fuel filters, brake pads, clutch plates, batteries, tires.

Engine Overhaul:

Detailed instructions for engine disassembly, inspection of components (pistons, cylinders, crankshaft, camshafts, valves), reassembly, and torquing specifications.

Carburetor Rebuild Adjustment:

Complete steps for disassembling, cleaning, inspecting, and reassembling the Keihin CV 40 carburetor, including idle speed and mixture adjustments.

Wheel And Tire Service:

Procedures for wheel removal, tire mounting and dismounting, balancing, and spoke tensioning.

Electrical Diagnostics:

Comprehensive troubleshooting guides using wiring diagrams, multimeter testing procedures for components like ignition coils, starter solenoids, and regulators.

Suspension Service:

Procedures for fork disassembly, seal replacement, oil replenishment, and rear shock absorber servicing or replacement.

Technical Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.

Torque Specifications:

Includes critical torque values for engine, transmission, suspension, and chassis fasteners.

Tolerances And Clearances:

Detailed specifications for component clearances, such as valve lash, piston ring gap, and bearing play, essential for proper engine rebuilds.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Searchability:

Text-searchable PDF for quick information retrieval.

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

883cc (53.9 cu in) and 1200cc (73.2 cu in) variants available

Bore X Stroke:

883cc: 3.00 in x 3.81 in (76.2 mm x 96.8 mm); 1200cc: 3.50 in x 3.81 in (88.9 mm x 96.8 mm)

Compression Ratio:

883cc: 8.4:1; 1200cc: 9.7:1 (typical, may vary slightly by model)

Valvetrain:

OHV, 2 valves per cylinder, pushrod actuated.

Horsepower:

Approx. 50-60 HP (varies by displacement and tuning)

Torque:

Approx. 50-65 ft-lbs (varies by displacement and tuning)

Fuel Delivery:

Carbureted (Keihin CV 40) on most models

Fuel Type:

Unleaded gasoline, minimum 87 octane

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Drive Type:

Primary drive: Chain; Final drive: Belt

📐 Dimensions

Length:

Approximately 89.1 inches (2263 mm) (varies by model)

Width:

Approximately 31.5 inches (800 mm) (varies by model)

Height:

Approximately 47.3 inches (1201 mm) (varies by model)

Wheelbase:

Approximately 60.0 inches (1524 mm) (varies by model)

Dry Weight:

Approximately 500-550 lbs (227-250 kg) (varies by model)

Fuel Capacity:

Approximately 3.1-4.8 gallons (11.7-18.2 L) (varies by model)

🛡️ Safety Features

Safety Ratings:

Motorcycles generally do not receive NHTSA or IIHS crash test ratings. Safety is primarily dependent on rider skill and adherence to road safety practices.

Active Features:

Disc brakes front and rear, responsive handling, rider control inputs.

Passive Features:

Frame integrity, rider position for visibility.

💡 Technology Features

Infotainment:

Basic instrumentation: speedometer, odometer, tachometer (optional/model dependent), indicator lights. No integrated infotainment systems.

🔧 Maintenance

Initial Service:

Typically at 1,000 miles (1,600 km) or 3 months.

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months for regular servicing (e.g., oil change, filter, inspection).

Spark Plug Replacement:

Refer to manual, typically around 10,000-15,000 miles (16,000-24,000 km).

Engine Oil:

Harley-Davidson Genuine V-Twin 20W-50 Motorcycle Oil or equivalent API SG, JASO MA approved.

Transmission Primary Chain Case Oil:

Harley-Davidson Genuine Primary Chain Lubricant or Formula+, SAE 80W-90.

Brake Fluid:

DOT 4 or DOT 5.1 (check specific model variant and caliper type as some may use DOT 5 silicone fluid; manual clarification is key).

Fork Oil:

Refer to manual for specific weight and type, typically SAE 10W.

Coolant:

Air-cooled, no coolant required.

Known Issues:

Early Evolution engine models could experience lifter noise, some oil leaks from seals, and potential issues with the voltage regulator or stator. Carburetor tuning can be critical for smooth operation.

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, is one of the oldest motorcycle manufacturers in the world, renowned for its V-twin engines and cruiser motorcycles.

Model Evolution:

The Sportster platform was introduced in 1957 and has undergone continuous evolution. The 2004 models represent a significant step with the introduction of a rubber-mounted engine, reducing vibration and improving rider comfort.

Production Years:

Sportster line in production since 1957; 2004 models are part of the Evolution engine era which began in the late 1980s.

Manufacturing Location:

United States (Milwaukee, Wisconsin, and other facilities).