🏷️ Basic Information

Make:

Harley Davidson

Model:

Sportster XLH

Year:

2004

Engine Family:

Evolution

Model Code:

XLH

👋 Introduction

Market Segment:

Cruiser motorcycle segment, known for its classic styling and V-twin engine character. The Sportster line is Harley-Davidson's entry-level platform but also a customizable icon.

Key Competitors 2004:

Indian Chief, various models from Japanese manufacturers (e.g., Honda Shadow, Yamaha V-Star, Kawasaki Vulcan), and other American V-twin manufacturers.

Sportster Appeal:

Customizable platform, iconic V-twin rumble, relatively accessible price point within the Harley-Davidson lineup, strong aftermarket support.

Target Audience:

Harley-Davidson motorcycle owners (DIY mechanics), independent repair shops, technicians specializing in American V-twins.

📋 Manual Details

Coverage Scope:

Comprehensive repair and overhaul of Harley Davidson Sportster XLH 2004 motorcycles.

Estimated Page Count:

Approximately 500-700 pages (typical for this era of comprehensive service manuals).

Manual Type:

Service Manual / Workshop Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, tuning, ignition system, fuel system (carburetor), lubrication system, cooling system (air-cooled).

Transmission Systems:

Clutch, transmission gear sets, primary drive, final drive, shift mechanism, transmission fluid service.

Chassis Systems:

Frame, front suspension (forks), rear suspension (shocks), wheels, tires, brakes (front and rear hydraulic), steering.

Electrical Systems:

Wiring diagrams, battery, charging system (alternator, regulator), ignition system, lighting, starter motor, switches, instrumentation, horn.

Fuel System:

Carburetor (likely Keihin CV40 or similar) disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel filter.

Bodywork And Trim:

Fenders, fuel tank, seat assembly, handlebars, controls, fenders, minor body panel removal and installation.

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid flush, tire pressure checks.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.

Major Repairs Overhauls:

Engine internal component replacement (pistons, rings, valves), transmission rebuild, suspension overhauls, brake caliper rebuilds.

Assembly Disassembly:

Step-by-step instructions for the removal and installation of all major components and sub-assemblies.

Wiring Diagrams:

Detailed electrical wiring schematics with component identification.

Depth Of Coverage:

Expert level; assumes technician proficiency in general motorcycle repair practices and the use of specialized tools. Covers everything from routine maintenance to complete engine and transmission overhauls.

📊 Manual Specifications

PDF Quality:

High-resolution scans or digitally created PDFs, optimized for clarity of text and diagrams. Searchable text is highly probable for digital versions.

Print Readability:

Designed for clear printing with legible diagrams and text. Font sizes and line weights are generally optimized for workshop environments.

Binding Type:

N/A (PDF format, no physical binding)

Paper Type:

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

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, Evolution (Evo) engine.

Displacement:

Commonly 883cc or 1200cc for the XLH series. The 2004 model year typically featured the 883cc Evolution engine as standard for the XLH model, with the 1200cc often designated as XL1200C/R/S.

Bore X Stroke 883Cc:

76.2 mm x 96.8 mm (3.00 in x 3.81 in)

Bore X Stroke 1200Cc:

88.8 mm x 96.8 mm (3.49 in x 3.81 in)

Compression Ratio 883Cc:

8.8:1 (typical)

Compression Ratio 1200Cc:

9.0:1 (typical)

Horsepower 883Cc:

Approx. 50-55 hp @ 6000 RPM

Torque 883Cc:

Approx. 55-60 lb-ft @ 3500-4000 RPM

Horsepower 1200Cc:

Approx. 65-70 hp @ 6000 RPM

Torque 1200Cc:

Approx. 70-75 lb-ft @ 3500-4000 RPM

Fuel Delivery:

Carbureted (typically Keihin CV40, requiring manual jetting and adjustment).

Fuel Type:

Unleaded gasoline, 87-91 octane recommended.

Ignition Type:

Electronic Ignition (CDI or similar module).

Oil Capacity:

Approx. 2.5-3.0 US quarts (2.4-2.8 liters) with filter change (check manual for exact spec).

Oil Type:

Harley-Davidson recommended V-Twin specific motorcycle oil, SAE 20W50 (or as specified in the manual, common for air-cooled engines).

🔧 Transmission

Transmission Type:

5-speed constant mesh manual transmission.

Optional Transmissions:

N/A for the 2004 XLH model. All Sportsters of this era featured the 5-speed.

Primary Drive:

Enclosed wet-type multi-plate clutch with chain drive to the transmission.

Final Drive:

Belt drive (commonly 132-tooth, 1.5-inch wide belt).

Transmission Fluid Capacity:

Approx. 1.0 US quart (0.95 liters) of Harley-Davidson transmission lubricant (or equivalent).

Transmission Fluid Type:

Harley-Davidson Formula +, Syn3, or equivalent 80W-90 gear oil or transmission fluid.

📐 Dimensions

Overall Length:

Approx. 88.2 inches (2240 mm) - varies slightly by model variant (e.g., custom, standard).

Wheelbase:

Approx. 59.6 inches (1514 mm).

Seat Height:

Approx. 26.0 inches (660 mm) unladen.

Dry Weight:

Approx. 495 lbs (225 kg) - varies slightly by model variant.

Gross Vehicle Weight Rating Gvwr:

Typically around 900-950 lbs (408-431 kg).

Fuel Capacity:

Approx. 3.5 US gallons (13.2 liters).

🛡️ Safety Features

Safety Ratings:

Motorcycles are not subject to the same NHTSA crash test ratings as cars. Safety is primarily dependent on rider skill and adherence to safe riding practices.

Braking System:

Dual hydraulic disc brakes (front and rear). Front typically 292mm disc, rear 292mm disc. Single piston calipers for front, dual piston for rear on some variants.

Lighting:

Headlight, tail light, brake light, turn signals (front and rear).

Chassis Design:

Steel frame for rigidity and durability.

Rider Ergonomics:

Designed for a planted, comfortable riding position, crucial for control.

💡 Technology Features

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, indicator lights (oil pressure, turn signals, high beam, engine diagnostics). No advanced infotainment features like Bluetooth or GPS typically found on modern bikes.

Driver Assistance Features:

N/A. Motorcycles of this era do not feature electronic driver assistance systems.

Connectivity Features:

N/A. No integrated connectivity features.

🔧 Maintenance

Initial Service Mileage:

First service typically at 1,000 miles (1,600 km).

Regular Service Interval:

Every 5,000 miles (8,000 km) or annually, whichever comes first. This includes oil and filter changes, drive belt inspection, brake checks, etc.

Engine Oil Change Interval:

Every 2,500-5,000 miles (4,000-8,000 km) or annually. The manual will specify the precise interval and oil type.

Spark Plug Replacement Interval:

Approximately every 10,000-15,000 miles (16,000-24,000 km). Check manual for specific plug type and gap.

Engine Oil Spec:

Harley-Davidson V-Twin specific motorcycle oil, SAE 20W50 (or 10W-50 depending on ambient temperature, as per manual).

Transmission Fluid Spec:

Harley-Davidson Formula +, Syn3, or SAE 80W-90 gear oil/transmission lubricant.

Brake Fluid Spec:

DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch friction plates, brake pads, tires, wheel bearings, belt drive components (e.g., belt, pulleys), fork seals.

Potential Engine Issues:

Carburetor tuning issues (idle instability, popping on deceleration), starter clutch wear, cam chain tensioner wear (though less common on Evo Sportsters compared to earlier Big Twins).

Potential Electrical Issues:

Wiring harness issues due to vibration, regulator/rectifier failure, battery charging problems.

Suspension Wear:

Fork seals can leak, rear shocks can lose damping over time.

📚 Vehicle History

Harley Davidson History:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and cultural impact.

Sportster Lineage:

The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running model families. It has evolved from its initial sporty roots to become a versatile cruiser platform known for its customization potential and approachable character.

Manufacturing Location:

Harley-Davidson motorcycles, including Sportsters, were primarily manufactured in Milwaukee, Wisconsin, USA during this period.

Key Updates 2004:

The 2004 model year saw significant updates to the Sportster line, including the introduction of a new frame with a larger backbone and revised geometry for improved handling and stability. It also marked the adoption of more modern braking systems and potentially updated electrical components.

🏆 Awards & Recognition

Sportster Market Perception:

Consistently recognized as a benchmark for customizability and accessible V-twin riding experience. Often praised for its distinctive character and aftermarket support.

Customer Satisfaction:

High customer satisfaction is often reported, driven by brand loyalty and the riding experience, though reliability can be a factor for some owners depending on maintenance.

Emissions Standards:

Designed to meet applicable emissions standards for motorcycles in the US market for the 2004 model year.