🏷️ Basic Information

Make:

Harley Davidson

Model:

Sportster XL1200C

Year:

2004

Product Name:

Harley Davidson Sportster XL1200C Custom 2004 Service Repair Manual

Product Description:

Harley Davidson Sportster XL1200C Custom 2004 Service PDF Manual / Workshop Repair.

👋 Introduction

Motorcycle Segment:

Cruiser, Custom

Target Audience:

Owners and independent mechanics seeking to perform maintenance, repairs, and customization on their Sportster XL1200C.

Competitors:

Other V-twin cruisers from brands like Indian, Victory (in later years), and some Japanese models offering similar styling and displacement.

Model Focus:

The XL1200C Custom emphasizes classic styling with chrome accents and a comfortable riding position.

Manual Value Proposition:

Provides detailed technical guidance to ensure proper maintenance and repair, maximizing the lifespan and performance of the motorcycle.

📋 Manual Details

Primary Coverage:

Repair and overhaul of Harley Davidson Sportster XL1200C Custom 2004

Technician Assumption:

Assumes technician is fully conversant with general motorcycle repair and maintenance.

Estimated Pages:

Variable (typically 500-800 pages for a comprehensive service manual, specific count not provided in product info)

Type:

Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Engine disassembly, assembly, inspection, repair, troubleshooting for Evolution V-Twin engine.

Fuel System:

Carburetor (CV) or Electronic Fuel Injection (EFI) systems, fuel pump, fuel tank, lines.

Ignition System:

Ignition module, coils, spark plugs, wiring.

Transmission:

Clutch, primary drive, transmission gears, shift mechanism, maintenance, and repair.

Drivetrain:

Belt drive system (rear), final drive belt inspection and replacement.

Brakes:

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

Suspension:

Front fork (telescopic), rear shock absorbers, swingarm, wheel bearings.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, wiring diagrams.

Frame And Bodywork:

Frame inspection, fenders, fuel tank, seat, handlebars, controls, body panel removal and installation.

Wheels And Tires:

Wheel removal and installation, tire mounting and balancing, spoke tension.

Maintenance:

Routine scheduled maintenance, fluid changes, lubrication, filter replacement, inspection checks.

Troubleshooting:

Diagnostic procedures for common and uncommon problems across all systems.

Repair:

Detailed step-by-step instructions for component disassembly, repair, and reassembly.

Overhaul:

Comprehensive instructions for complete engine and transmission overhauls.

Diagnostics:

Fault code interpretation (if applicable for EFI models), electrical system testing.

Specifications:

Torque specifications, clearances, fluid capacities, electrical values.

Depth:

Comprehensive, covering everything from basic maintenance to full engine rebuilds and complex diagnostics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely searchable text, allowing for quick keyword-based information retrieval.

Printability:

Designed for printing, with clear diagrams and legible text.

Binding:

N/A (Digital PDF, typically unbound)

Paper:

N/A (Digital PDF, no physical paper type)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1200 cc (73.2 cubic inches)

Bore X Stroke:

3.500 in. x 3.800 in. (88.9 mm x 96.5 mm)

Compression Ratio:

8.8:1

Valve Train:

Overhead valve (OHV), 2 valves per cylinder

Horsepower:

Approx. 65-70 HP (specific dyno figures vary)

Torque:

Approx. 70-75 ft-lbs (specific dyno figures vary)

Fuel Delivery:

Likely Carbureted (Keihin CV 40mm) or optional Electronic Fuel Injection (EFI) depending on specific sub-model or region for 2004. Manual should cover both possibilities if applicable.

Fuel Type:

Unleaded gasoline, minimum 87 octane

Oil Type:

Harley-Davidson SYN3 (Synthetic) SAE 20W50 or equivalent motorcycle-specific oil.

Oil Capacity:

3.0 US quarts (2.8 liters) with filter change.

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Primary Drive:

Duplex chain, 1.468:1 ratio

Final Drive:

Belt drive, 3.15:1 ratio

Transmission Fluid Type:

Harley-Davidson Transmission Lubricant (SYN3 or specific formula) or equivalent SAE 80W-90 gear oil.

Transmission Fluid Capacity:

22 US fluid ounces (0.65 liters)

📐 Dimensions

Length:

Approx. 89.1 inches (2263 mm)

Width:

Approx. 34.7 inches (881 mm)

Height:

Approx. 47.2 inches (1199 mm)

Wheelbase:

60.0 inches (1524 mm)

Ground Clearance:

4.8 inches (122 mm)

Dry Weight:

Approx. 560 lbs (254 kg)

Gvwr:

Not typically specified for motorcycles in the same way as cars, but payload capacity is relevant.

Fuel Capacity:

4.8 US gallons (18.2 liters)

🛡️ Safety Features

Crash Testing:

Motorcycles are not typically subjected to the same standardized crash testing as automobiles by organizations like NHTSA or IIHS. Safety features are vehicle design specific.

Braking System:

Dual front disc brakes, single rear disc brake. ABS was generally not standard on Sportsters in 2004 but may have been an option.

Lighting:

Halogen headlight, LED tail light, incandescent turn signals.

Frame Construction:

Steel, cradle frame design for stability.

Ergonomics:

Forward-mounted foot controls, laid-back riding posture contributing to rider comfort and control.

💡 Technology Features

Audio System:

Stock models typically do not include an integrated audio system. Owners often opt for aftermarket fairing or handlebar-mounted systems.

ABS:

Anti-lock Braking System (ABS) was generally an option for this model year, not standard. Manual should detail operation and maintenance if equipped.

Bluetooth:

No factory Bluetooth connectivity on stock 2004 models. Aftermarket solutions are available.

Gauge Cluster:

Analog speedometer, tachometer (often optional or integrated into a handlebar-mounted unit), fuel gauge, indicator lights.

🔧 Maintenance

First Service:

Typically 1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Services:

Every 5,000 miles (8,000 km) or 12 months for standard maintenance (oil changes, filter replacements, inspections). More frequent checks for belts, brakes, and tire pressure are recommended.

Engine Oil:

Harley-Davidson SYN3 SAE 20W50 or equivalent motorcycle-specific oil.

Transmission Oil:

Harley-Davidson Transmission Lubricant or SAE 80W-90 gear oil.

Primary Chain Case Oil:

Harley-Davidson Primary Chain Case Lubricant or SAE 80W-90 gear oil (often the same as transmission).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Vibration:

While the 2004 'Rubber Mount' frame improved this, earlier Sportster models were known for vibration. Check mounting points and any aftermarket accessories for wear.

Carburetor Issues:

CV carburetors can sometimes be finicky, requiring adjustments or rebuilds. Check for vacuum leaks or clogged jets.

Belt Wear:

The final drive belt should be inspected regularly for cracks, fraying, and proper tension. Replacement is typically at 30,000-50,000 miles depending on maintenance and riding conditions.

Electrical Connections:

Corrosion on electrical connectors can cause intermittent issues. Regular inspection and dielectric grease application are recommended.

📚 Vehicle History

Brand Origin:

Harley-Davidson Motor Company, founded in 1903 in Milwaukee, Wisconsin, USA. Iconic American motorcycle manufacturer.

Sportster Lineage:

The Sportster line dates back to 1957, evolving through various displacements and styling cues. The XL1200C represents a modern interpretation of the classic Sportster design.

Manufacturing Location:

United States (various Harley-Davidson facilities)

2004 Updates:

The 2004 model year saw the introduction of the new 'Rubber Mount' frame for Sportsters, which significantly improved vibration isolation compared to previous rigid frames.

🏆 Awards & Recognition

Model Accolades:

The Sportster line has consistently been recognized for its iconic styling and customization potential, making it a favorite among riders who personalize their machines. Specific awards for the 2004 XL1200C are not widely documented as a distinct model, but the Sportster platform itself is a perennial favorite.

Reliability:

Harley-Davidson Evolution engines are known for their durability and longevity with proper maintenance. The 2004 rubber-mount Sportsters are generally considered reliable.

Emissions Compliance:

Complies with applicable US EPA emissions standards for its model year. Manual will detail emission-related components and diagnostics.