Basic Information Identification Make: Harley Davidson Model: XL1200C Sportster Custom Year: 2004 Codes Engine Family: Evolution Chassis Code: XL Introduction Market Position Positioning: A foundational tool for owners and mechanics of the 2004 Harley Davidson XL1200C Sportster Custom, offering comprehensive repair and maintenance capabilities. Competitive Analysis Value Proposition: Provides factory-level repair information at a fraction of the cost of dealership services, empowering users to perform a wide range of tasks. Key Features Illustrations: Hundreds of photos and detailed illustrations guide users through procedures. Instructional Style: Numbered instructions, detailed substeps, notes, cautions, and warnings for clarity and safety. Searchability: PDF format allows for digital searching of terms and topics. Accessibility: Instant download eliminates shipping costs and wait times. Manual Details Coverage Areas General Information: Yes Maintenance: Yes Chassis: Yes Fuel System: Yes Cooling System: Yes (though typically air-cooled for this model) Engine: Yes Clutch: Yes Engine Lubrication System: Yes Engine Removal Installation: Yes Drive: Yes Transmission: Yes Wheels Tires: Yes Final Drive: Yes Brakes: Yes Suspension: Yes Steering: Yes Frame: Yes Electrical System: Yes Wiring Diagram: Yes Troubleshooting: Yes Page Count Estimated Pages: Hundreds Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered All Systems: Yes, comprehensive coverage of all major mechanical, electrical, and chassis systems. Procedures Included Repair Procedures: Detailed step-by-step instructions for all repair procedures. Maintenance Procedures: Routine maintenance tasks, inspections, and adjustments. Troubleshooting Guidance: Systematic diagnostic procedures for identifying and resolving issues. Technical Depth Depth: Factory-level detail suitable for both DIY enthusiasts and professional mechanics, covering complete disassembly and reassembly. Manual Specifications File Format File Format: PDF Print Quality Printable: Yes, printable without restriction. Binding Type Binding: Digital download (printable). Paper Type Paper Type: N/A (Digital) Software Requirements Reader Requirement: Adobe PDF Reader Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-twin Displacement: 1200cc (73.4 cubic inches) Bore X Stroke: 3.496 in. x 3.800 in. (88.8 mm x 96.5 mm) Compression Ratio: 9.0:1 (typical for this era) Performance Horsepower: Approximately 65-70 HP (estimated, actual figures can vary) Torque: Approximately 70-75 lb-ft (estimated, actual figures can vary) Fuel System Fuel Delivery: Carburetor (Keihin CV 40mm typical for this model year, though some might have early EFI implementations depending on market - manual should clarify) Ignition System: Electronic ignition Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multi-plate Primary Drive: Duplex chain, rubber isolated, 1.36:1 ratio Final Drive: Belt drive, 2.75:1 ratio Dimensions Exterior Wheelbase: 60.0 in. (1524 mm) Length: 89.2 in. (2266 mm) Seat Height Laden: 27.0 in. (686 mm) Weights Dry Weight: Approx. 596 lbs (270 kg) Gross Vehicle Weight Rating: Approx. 965 lbs (438 kg) Safety Features Ratings Crash Test Ratings: N/A for motorcycles in this era, focus is on component integrity and operational safety. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Lighting: Headlight, taillight, brake light, turn signals. Technology Features Infotainment Infotainment System: Base model, typically no integrated infotainment system beyond basic gauges (speedometer, tachometer, odometer, fuel gauge). Driver Assistance Driver Assistance Features: None (typical for motorcycles of this era). Connectivity Connectivity Features: None (typical for motorcycles of this era). Maintenance Service Intervals Oil Change Interval: Typically every 2,500-5,000 miles or annually, whichever comes first (refer to manual for exact specifications). Primary Chain Tensioner Check: Frequent checks recommended, often at oil change intervals, as it's a known wear item. Spark Plug Replacement: Approximately every 10,000-15,000 miles (refer to manual). Fluid Specifications Engine Oil: Harley-Davidson 20W50 SYN3 (or equivalent API CG-4 rated motorcycle oil), typically 3.0 US quarts (2.8 liters) for engine oil. Primary Chain Case Oil: Harley-Davidson primary fluid or Syn3, typically 1.0 US quart (0.95 liters). Transmission Oil: Harley-Davidson Transmission Fluid or suitable 75W-90 synthetic gear oil, typically 0.95 US quarts (0.9 liters). Brake Fluid: DOT 4 (for hydraulic clutch and brake systems). Known Issues Primary Chain Tensioner: The stock spring-loaded primary chain tensioner can wear out, leading to excessive chain slap and potential damage if not replaced with an upgraded hydraulic tensioner. Carburetor Tuning: CV carburetors can require periodic adjustments for optimal performance, especially after modifications or with age. Rear Shocks: Stock rear shocks may offer limited adjustability and damping, leading some owners to upgrade for improved ride quality. Vehicle History Brand Heritage Manufacturer Origin: United States Model Evolution Sportster Lineage: The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, known for its nimble handling and V-twin power. Xl1200C Custom Features: The 'Custom' variant often features a distinctive styling package, including chrome accents, pulled-back handlebars, and a solo seat, with a lower seat height for comfortable cruising. Production Production Period: Sportster models have been in continuous production since 1957. The XL1200C specifically gained popularity in the late 1990s and 2000s. Awards & Recognition Recognitions Motorcycle Awards: While specific awards for the 2004 model are...