Target Audience:
Harley-Davidson owners, independent repair shops, and DIY mechanics.
Value Proposition:
Provides authoritative, factory-level repair and maintenance information to maintain and repair the 2004 Sportster XLH effectively.
Advantage:
Official factory documentation ensures accuracy and completeness over third-party aftermarket manuals.
Core Benefit:
Empowers users with the knowledge to perform all necessary maintenance and repairs, saving time and money.
Content Highlight:
Includes detailed wiring diagrams, torque specifications, and procedural steps critical for correct repair.
Primary Coverage:
Complete Factory Service and Repair
Specific Models Covered:
All Harley-Davidson Sportster XLH models for the 2004 model year
Estimated Page Count:
Hundreds (Exact count not specified, but described as 'complete' and allowing for full printing)
Type:
Factory Service Repair Manual (FSM)
Engine Systems:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system (air-cooled), fuel delivery (carbureted and early EFI depending on sub-model variant), ignition system, exhaust system, starting system.
Drivetrain Systems:
Clutch operation and adjustment, transmission internal operation and repair, final drive belt inspection and adjustment.
Chassis Systems:
Frame inspection and repair, front fork assembly and service, rear shock absorber and suspension service, steering head bearing maintenance, wheel and tire service, brake system overhaul (front and rear), electrical system diagnostics and component replacement, lighting system, battery maintenance, wiring diagrams.
Bodywork And Trim:
Fender removal and installation, fuel tank servicing, seat removal, handlebar and control adjustments.
Maintenance Procedures:
Routine servicing, oil changes, filter replacements, spark plug replacement, drive belt adjustment, brake fluid flush, general inspection.
Repair Procedures:
Engine rebuilds, transmission overhaul, suspension fork seal replacement, brake caliper rebuild, electrical component troubleshooting and replacement.
Troubleshooting Guides:
Diagnostic charts and symptom-based troubleshooting for common and complex issues.
Depth:
Comprehensive. Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagnostic Capabilities:
Detailed procedures for diagnosing electrical faults, engine performance issues, and chassis component failures.
Searchability:
Likely text-searchable, facilitating quick access to specific information.
Print Recommendation:
Optimized for printing, allowing users to create a physical copy of specific sections or the entire manual.
Suggested Binding:
Comb binding or spiral binding for easy page turning during workshop use.
Recommended Paper:
Durable, workshop-grade paper to withstand grease and frequent handling.
Engine Family:
Harley-Davidson Evolution (often referred to as 'Evo' or 'Sportster Evolution')
Engine Configuration:
Air-cooled, 45-degree V-twin
Displacement:
Typically 883cc or 1200cc for the 2004 Sportster line. Specific variant not detailed in product info, but manual will cover both.
Bore X Stroke:
883cc: 3.00 in x 3.81 in (76.2 mm x 96.8 mm); 1200cc: 3.498 in x 4.25 in (88.8 mm x 107.95 mm) - specific to variant.
Compression Ratio:
Varies by displacement and specific model variant (e.g., ~8.4:1 for 883, ~9.7:1 for 1200).
Horsepower:
Not explicitly stated, but typically around 50-55 HP for 883cc and 60-70 HP for 1200cc models.
Torque:
Not explicitly stated, but typically around 50-55 lb-ft for 883cc and 60-70 lb-ft for 1200cc models.
Fuel Delivery:
Carbureted (Keihin CV carburetor) or Electronic Fuel Injection (EFI) depending on the specific Sportster XLH model variant for 2004. Manual will cover the relevant system.
Fuel Type:
Unleaded gasoline, 91 octane (or higher) recommended.
Oil Type:
Harley-Davidson Genuine V-Twin Oil (or equivalent API SG or higher, SAE 20W50). Manual will specify exact part numbers.
Oil Capacity:
Approximately 3 US quarts (2.8 liters) with filter change. Manual will provide precise capacity.
Type:
5-speed constant mesh, helical gear transmission.
Options:
N/A for this model year and platform.
Drive Type:
Primary drive via duplex chain; final drive via V-belt.
Transmission Fluid:
Harley-Davidson primary chaincase lubricant (or equivalent SAE 80W-90 GL-5 gear oil). Manual will specify exact part numbers and capacity.
Wheelbase:
Approximately 59.8 inches (1519 mm) - varies slightly by model.
Seat Height:
Approximately 26.3 inches (668 mm) - unladen, varies by model.
Dry Weight:
Approximately 470-500 lbs (213-227 kg) depending on the specific XLH model variant.
Gvwr:
Specified in the manual, typically around 930-960 lbs (422-435 kg).
Crash Test Data:
Motorcycles are not typically rated by agencies like NHTSA or IIHS. Safety relies on design and rider skill. Manual focuses on mechanical integrity.
Braking System:
Hydraulically actuated disc brakes front and rear. Dual piston front caliper, single piston rear caliper.
Tire Specifications:
Tubeless tires. Front: 3.00-19 or 100/90-19. Rear: 150/80-16 or similar. Manual will list exact OEM specifications and recommended replacements.
Lighting:
Halogen headlight, taillight, brake light, turn signals. Manual covers electrical diagnostics for these.
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes oil change, filter change, primary chain adjustment, and general inspection.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter. Includes more comprehensive checks, fluid changes as needed, spark plug replacement etc. Detailed schedule provided in manual.
Engine Oil:
Harley-Davidson Genuine V-Twin Oil (or equivalent SAE 20W-50, API SG or higher). Specific part numbers: 62600004 (quart) or similar.
Primary Chaincase Lubricant:
Harley-Davidson Primary Chaincase Lubricant (or equivalent SAE 80W-90 GL-5 gear oil). Specific part numbers: 99847-05 (quart) or similar.
Brake Fluid:
DOT 5.1 Silicone-based brake fluid. Manual will specify replacement intervals and bleeding procedures. Harley part number: 99951-89.
Fork Oil:
Specific weight and type (e.g., Harley-Davidson Type 'E' or 'B' fork oil) will be detailed in the manual. Capacity per fork leg is typically around 8.7 US fl oz (258 ml).
Common Wear Items:
Clutch cable, drive belt, fork seals, wheel bearings, brake pads, and spark plugs are common wear items requiring periodic inspection and replacement.
Electrical Quirks:
Some owners report issues with voltage regulators or starter solenoids, though the 2004 models are generally robust. The manual provides diagnostic steps for these.
Engine Performance:
Carbureted models may require occasional carb cleaning and adjustment. EFI models might need periodic idle speed control adjustments. Manual details these procedures.
Founding:
Harley-Davidson Motor Company founded in Milwaukee, Wisconsin, 1903.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest continuously produced motorcycle model. The 2004 models utilize the Evolution engine, introduced in 1986, marking a significant modernization.
Manufacturing Location:
United States (typically Milwaukee, Wisconsin or York, Pennsylvania plants).
Model Year Significance:
The 2004 model year Sportster represented continued refinement of the Evolution engine platform, with subtle updates and options.
Model Awards:
Specific awards for the 2004 Sportster XLH are not widely documented as distinct from the model line's overall reputation for customization and performance in its class.
Reliability Ratings:
Generally considered reliable when properly maintained. The Evolution engine is known for its durability. The manual is key to maintaining this.
Manual Quality:
Official Harley-Davidson factory documentation ensures adherence to all internal engineering and service standards.