🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2004

Engine Variant:

XLH (typically denotes the Evolution V-Twin engine, specific displacement needs confirmation based on sub-model variants like XL883, XL1200)

Chassis Code:

XL Series

👋 Introduction

Market Position:

The Harley-Davidson Sportster XLH series represents a significant segment of the cruiser market, known for its classic styling, V-twin rumble, and customizability. The 2004 model year is part of the Evolution engine era, a robust and reliable platform.

Competitive Analysis:

Competes with other American and Japanese V-twin cruisers in its class, emphasizing heritage and rider engagement. The Sportster is often seen as an accessible entry point into the Harley-Davidson brand.

Key Features:

Iconic V-twin engine, traditional styling, rider-friendly ergonomics, strong aftermarket support, and a legacy of customization. The 2004 model year is notable for the introduction of the rubber-mounted Evolution engine for reduced vibration.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Page Count:

710

Manual Type:

Service Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, disassembly, assembly, component inspection, tuning, performance adjustments (carburetor, ignition timing, etc.)

Transmission:

Gearbox disassembly, assembly, inspection, clutch operation, primary drive system service

Electrical System:

Ignition system, charging system, lighting, starter motor, wiring diagrams, component testing, troubleshooting electrical faults

Fuel System:

Carburetor service and adjustment (e.g., Keihin CV carburetor), fuel tank, fuel lines, fuel pump (if applicable)

Brake System:

Brake caliper service, master cylinder, brake lines, bleeding procedures, pad replacement, rotor inspection

Suspension:

Front fork service (oil change, seal replacement), rear shock absorber service, adjustments

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and pivot bearing service

Bodywork And Trim:

Fender removal/installation, tank mounting, seat service, minor body panel adjustments

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment, battery maintenance

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting for common issues, fault code interpretation (if applicable)

Repair:

Detailed step-by-step instructions for component repair and replacement across all major systems

Diagnostics:

Methods for diagnosing mechanical and electrical problems, including specific tests and measurements

Depth:

Comprehensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and tolerances.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans suitable for printing. Includes clear diagrams and schematics.

Binding Type:

Not applicable (Digital PDF)

Paper Type:

Not applicable (Digital PDF)

Searchability:

Searchable text enabled for quick information retrieval.

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Bore X Stroke:

XL883: 3.00 in x 3.75 in (76.2 mm x 95.25 mm); XL1200: 3.496 in x 4.13 in (88.8 mm x 104.9 mm) - *Exact displacement for specific XLH variants should be verified from the manual.*

Displacement:

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

Compression Ratio:

Typically around 9.0:1 to 9.7:1 (varies by specific engine variant)

Valve Train:

Overhead valve (OHV), 2 valves per cylinder

Horsepower:

Approx. 50-60 HP (varies significantly by displacement and tuning)

Torque:

Approx. 55-65 ft-lbs (varies significantly by displacement and tuning)

Fuel Delivery:

Carbureted (typically Keihin 40mm CV carburetor on most 2004 models)

Fuel Type:

Unleaded gasoline, minimum 89 octane recommended

Oil Type:

Harley-Davidson recommended V-Twin motorcycle oil (e.g., SAE 20W50 or 10W30 depending on climate and specific recommendations)

Oil Capacity:

Approx. 3 quarts (2.8 liters) for engine/transmission oil – *refer to manual for exact capacity and checking procedure.*

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Primary Drive:

Chain drive, enclosed in primary chaincase

Final Drive:

Belt drive

Transmission Oil:

Harley-Davidson Formula + Transmission/Primary Chaincase Lubricant

📐 Dimensions

Length:

Varies by specific Sportster model (e.g., ~88 inches / 2235 mm)

Width:

Varies by specific Sportster model (e.g., ~33 inches / 838 mm)

Height:

Varies by specific Sportster model (e.g., ~47 inches / 1194 mm)

Dry Weight:

Approx. 500-550 lbs (227-250 kg) depending on model and options

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle VIN plate and manual for exact specification

Fuel Capacity:

Approx. 3.0-3.1 gallons (11.4-11.7 liters) depending on tank size

🛡️ Safety Features

Safety Ratings:

Motorcycle safety is primarily rider-dependent. The manual provides procedures to ensure mechanical integrity for safe operation.

Active Safety:

Brake system (discs front and rear), steering geometry designed for stability. No electronic rider aids like ABS typically found on base 2004 models.

Passive Safety:

Robust frame construction, rider positioning for control. The manual's emphasis on proper maintenance contributes to overall rider safety.

💡 Technology Features

Infotainment System:

Basic instrumentation (speedometer, tachometer on some models, odometer, trip meter, indicator lights). No integrated infotainment systems or advanced electronics found on modern motorcycles.

Driver Assistance:

None.

Connectivity:

None.

Lighting System:

Halogen headlight, incandescent taillight and turn signals.

🔧 Maintenance

Initial Service:

Refer to the owner's manual, typically around 1,000 miles (1,600 km) for first service (oil change, filter, inspection).

Regular Maintenance:

1,000-mile (1,600 km) or 5,000-mile (8,000 km) service intervals for oil changes, filter replacement, and inspections. Transmission/primary oil changes typically every 2,500 miles (4,000 km) or annually. *Consult the manual for specific, detailed intervals.*

Engine Oil:

Harley-Davidson V-Twin Motor Oil SAE 20W50 (or 10W30 for colder climates). Equivalent API SG or higher quality oil.

Transmission Primary Oil:

Harley-Davidson Formula + Transmission/Primary Chaincase Lubricant or equivalent.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Specific weight of fork oil as recommended by Harley-Davidson for the 2004 Sportster (e.g., 10W).

Common Issues:

Carburetor tuning variations, potential oil leaks from common areas (e.g., primary cover, rocker boxes), clutch adjustment sensitivity, fork seal leaks. The manual will guide on diagnosing and rectifying these.

Oil Filter Part Number:

Commonly 63731-98 or 63796-77 (verify based on specific engine displacement and model variant)

Spark Plug Part Number:

Typically Harley-Davidson OEM or equivalent (e.g., NGK, Champion - specific part number to be found in the manual).

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of producing V-twin engines and cruiser-style motorcycles.

Model Evolution:

The Sportster line, introduced in 1957, has evolved significantly. The 2004 model year marked a key transition with the rubber mounting of the Evolution engine, improving rider comfort and reducing vibration compared to earlier solid-mount models.

Production Location:

Manufactured in the United States.

🏆 Awards & Recognition

Industry Recognition:

The Sportster line itself is a long-standing and recognized model within the cruiser motorcycle segment, synonymous with the Harley-Davidson brand's appeal. Specific awards for the 2004 model year are less common than for overall brand or model lineage.

Customer Satisfaction:

Generally high due to brand loyalty and the bike's character, though mechanical robustness is a continuous area of discussion and maintenance focus.