Harley-Davidson Sportster 2004 Service Repair Manual

常规价格: $16.99
促销价: $16.99
常规价格
单价: 单价

🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Engine Type: V-Twin Evolution (Air-Cooled) Engine Displacement Cc: 883cc and 1200cc (depending on specific Sportster model) Generation Generation: Generation 2 (XL Evolution...

23 people are viewing this right now

类型: Motorcycle

斯库: 472656

标签: 2004 Harley Davidson Misc Motorcycle Motorcycles Sportster

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Engine Type:

V-Twin Evolution (Air-Cooled)

Engine Displacement Cc:

883cc and 1200cc (depending on specific Sportster model)

Generation

Generation:

Generation 2 (XL Evolution Engine, introduced 1986)

👋 Introduction

Market Position

Motorcycle Segment:

Cruiser / Standard Motorcycle

Target Audience:

Owners and independent mechanics seeking in-depth repair and maintenance knowledge for their Harley-Davidson Sportster.

Competitive Analysis

Competitors 2004:

Indian Chief, Triumph Bonneville, various Japanese cruisers (e.g., Yamaha V-Star, Honda Shadow, Kawasaki Vulcan).

Key Features

Sportster Identity:

Known for its classic styling, accessible riding position, and V-twin engine rumble. Offers a blend of vintage aesthetics with modern (for the era) engineering.

Manual Value Proposition:

Provides the technical foundation for owners to maintain and repair their motorcycles, potentially saving on dealership service costs and enabling customization.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Downloadable Digital File (likely PDF)

Page Count

Page Count:

Undisclosed (typical service manuals are 500-1000+ pages)

📖 Manual Coverage

Systems Covered

Engine:

Full engine overhaul, inspection, repair, tuning, internal components (pistons, rings, valves, camshafts, crankshaft), cylinder heads, cooling system (air cooling).

Fuel System:

Carburetion (Keihin CV or similar) and/or Fuel Injection (EFI) systems, fuel pump, fuel filter, fuel lines, throttle body, injectors.

Ignition System:

Ignition module, coils, spark plugs, wiring, timing.

Transmission:

5-speed constant mesh transmission, clutch assembly, primary drive, final drive (belt drive), gear inspection, lubrication, repair.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery, lighting (headlight, taillight, turn signals), instrumentation, horn, electrical component troubleshooting.

Brakes:

Hydraulic front and rear brake systems, calipers, master cylinders, brake lines, brake pads, rotors, bleeding procedures, adjustments.

Suspension:

Front fork (telescopic) disassembly, inspection, oil replacement, seals, rear shock absorbers, swingarm, linkage, adjustments.

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearings, hub maintenance, spoke tensioning.

Bodywork And Trim:

Fenders, fuel tank removal/installation, seat, handlebars, controls, fairings (if applicable to specific models), trim pieces.

Procedures Included

Maintenance:

Routine service, oil changes, filter replacements, spark plug service, chain/belt adjustment, lubrication points, fluid checks and changes.

Troubleshooting:

Diagnosis of common problems, symptom-based troubleshooting charts, electrical diagnostics, engine performance issues.

Repair:

Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all covered systems.

Technical Data:

Specifications for torque values, clearances, fluid capacities, electrical resistance, diagnostic codes.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers basic maintenance through to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and factory specifications.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format) - Assumed for downloadable manuals.

Searchable Text:

Likely to be text-searchable, enabling quick location of specific topics.

Printable:

Typically PDF files are printable, allowing for on-bench use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Evolution (often referred to as 'Evo')

Engine Configuration:

90-degree V-twin, air-cooled

Bore X Stroke 883Cc:

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

Bore X Stroke 1200Cc:

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

Valve Train:

Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.

Performance

Horsepower 883Cc Est:

Approx. 50-55 HP

Torque 883Cc Est:

Approx. 55-60 ft-lbs

Horsepower 1200Cc Est:

Approx. 65-70 HP

Torque 1200Cc Est:

Approx. 70-75 ft-lbs

Fuel System

Carburetor 883Cc:

Keihin CV 40mm (common)

Fuel Injection 1200Cc:

Likely Sequential Port Fuel Injection (EFI) for 2004 models, with specific system details in manual.

Fuel Type:

Unleaded gasoline, minimum 87 octane recommended.

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh

Clutch Type:

Wet, multi-plate, cable-actuated

Final Drive:

Belt drive

Features

Gear Ratios:

Specific gear ratios for each of the 5 speeds will be detailed in the manual.

Transmission Fluid:

Manual will specify Harley-Davidson recommended transmission lubricant (e.g., Syn-3 or specific weight gear oil).

📐 Dimensions

Exterior

Wheelbase Est:

Approx. 59.9 inches (1521 mm)

Seat Height Est:

Approx. 26.1 inches (663 mm)

Weights

Dry Weight Est:

Approx. 500-530 lbs (227-240 kg) depending on model/configuration.

Fuel Capacity:

Approx. 3.1 - 4.5 gallons (11.7 - 17.0 L) depending on specific Sportster model (e.g., Hugger, Custom, Roadster).

Tire Size Front:

Commonly 100/90-19 or similar, manual will confirm specific fitment.

Tire Size Rear:

Commonly 130/90-16 or 150/80-16, manual will confirm specific fitment.

Wheel Bolt Pattern:

N/A (Spoked wheels with axle mounting)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not subjected to standardized crash testing like automobiles.

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Lighting:

Halogen headlight, LED or incandescent taillight and turn signals for visibility.

Passive Features

Frame Construction:

Robust steel frame designed for stability.

💡 Technology Features

Infotainment

Infotainment System:

Base model; typically features analog speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems like on touring models.

Driver Assistance

Driver Assistance Features:

None standard. Focus is on core riding experience.

Connectivity

Connectivity Features:

None standard. Designed for a purist riding experience.

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer (optional on some models), neutral indicator, oil pressure light, turn signal indicators.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,500-5,000 miles or annually, whichever comes first. Manual will specify exact intervals and conditions.

Primary Chain Tension:

Check and adjust primary chain tension at regular intervals (e.g., 5,000 miles). Specific procedure and tension specs in manual.

Spark Plug Replacement:

Recommended every 5,000-10,000 miles. Manual will specify correct plug type and gap.

Fluid Specifications

Engine Oil Type:

Harley-Davidson recommends specific V-twin motorcycle oils (e.g., Harley-Davidson 20W50 Synthetic or equivalent).

Engine Oil Capacity:

Approx. 3 quarts (2.8 L) for most Sportster models. Manual will provide exact capacity with filter change.

Transmission Fluid Type:

Harley-Davidson recommends specific transmission lubricant, often a heavy-duty gear oil or Syn-3. Manual will list part numbers and specifications.

Primary Chain Case Oil Type:

Harley-Davidson recommends a primary lubricant, often a specific weight oil or Syn-3. Manual will specify.

Known Issues

Carburetor Performance:

CV carburetors can sometimes require tuning or recalibration for optimal performance, especially with aftermarket modifications.

Belt Drive Tension:

Incorrect belt tension can lead to premature wear on the belt and pulleys. Manual details proper tensioning procedures.

Fork Seals:

Fork seal leaks can occur over time, requiring replacement. Manual provides detailed fork service.

Charging System Issues:

Occasional issues with regulator/rectifier or stator can affect battery charging. Manual offers troubleshooting for these.

📚 Vehicle History

Brand Heritage

Harley Davidson Legacy:

Harley-Davidson, founded in 1903, is one of the oldest motorcycle manufacturers globally, renowned for its V-twin engines and distinctive styling.

Model Evolution

Sportster Lineage:

The Sportster line dates back to 1957, evolving significantly over the decades. The 2004 models represent a mature phase of the Evolution engine platform.

Production

Manufacturing Location:

Primarily manufactured in the United States.

Model Variants 2004:

Included Sportster 883, Sportster 883 Hugger, Sportster 883 Custom, Sportster 1200 Custom, Sportster 1200 Roadster, Sportster 1200 Sport (depending on market availability).

🏆 Awards & Recognition

Recognitions

Sportster Market Impact:

The Sportster is a cultural icon and a significant model in motorcycle history, often praised for its customization potential and enduring appeal.

Ratings

Industry Reviews 2004:

Reviews from 2004 would likely praise its styling, V-twin character, and accessible price point relative to larger Harley models.

Certifications

Emissions Compliance:

The manual will likely contain information regarding emissions control systems relevant to the EPA or other regulatory bodies for the specified model years.