Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Sportster XL owners, DIY mechanics, independent repair shops.
Key Competitors 2004:
Triumph Bonneville, Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series, Indian Chief.
Manual Value Proposition:
Provides factory-accurate procedures, diagrams, and specifications crucial for maintaining and repairing the 2004 Sportster XL, saving time and money compared to dealership service.
Engine:
Engine assembly, disassembly, overhaul, troubleshooting, oiling system, lubrication, cooling system (air-cooled), fuel system (carbureted and early EFI for 1200 models), ignition system, starting system, charging system.
Transmission:
Clutch, primary drive, transmission case, gears, shifting mechanism, final drive, lubrication.
Chassis:
Frame, suspension (front fork and rear shock absorbers), steering, wheels, tires, brakes (front and rear hydraulic disc), swingarm.
Electrical:
Wiring diagrams, lighting, instrumentation, ignition switches, battery, starter motor, alternator, fuses, relays, electronic control modules (ECM for EFI models), diagnostic connectors.
Bodywork:
Fenders, fuel tank, seat, handlebars, controls, footpegs, exhaust system, emblems, trim.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug service, chain adjustment, brake fluid checks, tire pressure checks, lubrication points.
Repair And Overhaul:
Engine rebuilding, transmission rebuilding, fork seal replacement, brake caliper service, electrical component replacement, exhaust system installation/replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (for EFI models), electrical system diagnostics.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, detailed electrical troubleshooting, and component-level repair.
Engine Type:
Air-cooled, Evolution (V-Twin)
Engine Displacement 883:
883 cc (53.7 cu in)
Engine Displacement 1200:
1200 cc (73.2 cu in)
Bore Stroke 883:
3.190 in x 3.500 in (81.0 mm x 88.9 mm)
Bore Stroke 1200:
3.492 in x 3.800 in (88.7 mm x 96.5 mm)
Compression Ratio 883:
8.8:1
Compression Ratio 1200:
9.0:1
Horsepower Approx 883:
54 hp @ 6000 rpm (estimated)
Torque Approx 883:
50 lb-ft @ 4000 rpm (estimated)
Horsepower Approx 1200:
60 hp @ 5200 rpm (estimated)
Torque Approx 1200:
68 lb-ft @ 3500 rpm (estimated)
Fuel Delivery 883:
Keihin CV Carburetor (1998-2006 models)
Fuel Delivery 1200:
Keihin CV Carburetor (1998-2006 models) or Electronic Fuel Injection (EFI) depending on sub-model and emissions compliance.
Fuel Type:
Unleaded gasoline, 87 octane or higher
Crash Test Ratings:
Motorcycles are not subjected to standardized crash testing like automobiles.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals.
Frame Construction:
Steel cradle frame for structural integrity.
Engine Guard Options:
Optional engine guards available for leg protection.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter
Oil Change Interval:
Every 2,500 miles (4,000 km) or 6 months (recommended by many owners for optimal engine life).
Engine Oil:
Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG or higher specification). Specific oil type and capacity detailed in manual.
Transmission Primary Chain Case Oil:
Harley-Davidson Formula+ Transmission/Primary Chaincase Lube (or equivalent SAE 50 motorcycle transmission oil).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Fork Oil:
Specific weight and type varies by model variant, typically SAE 10W or equivalent.
Carburetor Tuning:
CV carburetor can require periodic adjustment for optimal performance and emissions. Manual covers tuning procedures.
Belt Drive Alignment:
Proper belt tension and alignment are critical; manual details adjustment procedures.
Wiring Harness Wear:
Some localized wear can occur over time; manual provides detailed wiring diagrams for diagnosis.
Suspension Leaks:
Front fork seals and rear shocks can eventually require service or replacement; manual covers overhaul.
Brand Origin:
Harley-Davidson Motor Company, founded 1903 in Milwaukee, Wisconsin, USA.
Sportster Introduction:
The Sportster line was introduced in 1957, becoming one of Harley-Davidson's longest-running and most iconic models. The 2004 model represents the Evolution engine era.
Key Changes 2004:
Introduction of the rubber-isolated powertrain for reduced vibration, significantly improving rider comfort. This was a major update for the Sportster line.
Manufacturing Location:
United States (e.g., Milwaukee, Wisconsin; York, Pennsylvania)
