Target Audience:
Harley-Davidson XL883 Sportster owners, independent repair shops, DIY enthusiasts
Value Proposition:
Provides official factory-level repair information, crucial for maintaining original specifications and resale value
Manual Attribute:
Official factory content ensures accuracy and completeness, crucial for this model year's specific components.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, fuel, ignition, exhaust
Transmission Drivetrain:
Clutch, gearbox, primary drive, final drive, chain maintenance
Chassis Frame:
Frame inspection, suspension, steering, wheels, tires
Braking System:
Front and rear brake system service, hydraulic components, bleeding
Electrical System:
Battery, charging system, ignition system, lighting, instrumentation, wiring diagrams, starter motor
Fuel System:
Carburetor (Keihin CV), fuel tank, fuel lines, fuel filter replacement
Maintenance Tasks:
Routine checks, oil changes, filter replacements, spark plug service, cable adjustments, lubrication points
Repair Procedures:
Step-by-step instructions for component replacement and repair
Troubleshooting Guides:
Diagnostic procedures for common and uncommon problems
Performance Tuning:
Carburetor tuning, ignition timing adjustments, exhaust system modifications advice
Wiring Diagrams:
Detailed electrical schematics for accurate fault diagnosis
Depth:
Comprehensive (from basic maintenance to full engine rebuilds)
Engine Displacement:
883 cc (53.9 cu in)
Engine Bore Stroke:
3.00 in x 3.8125 in (76.2 mm x 96.8 mm)
Claimed Horsepower:
Approx. 55 hp @ 6000 rpm
Claimed Torque:
Approx. 62 ft-lb @ 3200 rpm
Fuel Delivery:
Keihin CV 40mm Carburetor
Fuel Type Recommendation:
Unleaded gasoline, minimum 91 octane (RON + MON)/2 (AKI)
Ignition Type:
Electronic, with single fire ignition coil
Length:
Approx. 89.2 in (2266 mm)
Width:
Approx. 32.1 in (815 mm)
Height:
Approx. 46.7 in (1186 mm)
Dry Weight:
Approx. 504 lbs (228.6 kg)
Gross Vehicle Weight Rating:
Approx. 960 lbs (435.4 kg)
Fuel Capacity:
3.1 gal (11.7 L)
Oil Capacity:
3.0 US qt (2.8 L) (with filter)
Safety Standard:
Industry standard for motorcycle safety of the era
Braking System:
Dual-piston caliper front and rear brakes
Suspension Setup:
Adjustable rear shock absorbers for ride height and damping
Lighting:
Halogen headlamp, LED tail lamp, standard turn signals
Infotainment System:
Basic instrumentation: Speedometer, Tachometer (optional on some trims), Odometer, Trip meter, Fuel gauge, Indicator lights.
Driver Assistance Features:
N/A for this model year.
Connectivity Options:
N/A for this model year.
First Service Mileage:
1000 miles (1600 km) or 6 months
Subsequent Service Mileage:
5000 miles (8000 km) or 12 months (whichever comes first)
Engine Oil Change Interval:
Every 2500 miles (4000 km) or 6 months
Engine Oil Type:
Harley-Davidson 20W50 (or equivalent API SG or higher)
Primary Chaincase Oil Type:
Harley-Davidson Formula + Transmission/Primary Chaincase Lubricant (SAE 50W)
Common Wear Items:
Clutch wear, front fork seals, battery terminal corrosion
Potential Electrical Gremlins:
Wiring harness chafing, voltage regulator issues (especially on earlier rubber mount models)
Carburetor Tuning Quirks:
Keihin CV carburetors can require fine-tuning for optimal performance and starting, especially at altitude or with aftermarket exhausts.
Exhaust Gaskets:
Exhaust flange gaskets can deteriorate and cause leaks over time.
Brand Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Sportster Lineage:
The Sportster line, introduced in 1957, is known for its lightweight, nimble performance compared to larger Harley-Davidson models.
2004 Updates:
The 2004 model year saw the introduction of the rubber-mounted Evolution engine for reduced vibration, a significant upgrade.
Manufacturing Location:
USA (Milwaukee, Wisconsin)
