🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200C Sportster Custom Year: 2004 Vehicle Type: Motorcycle Codes Engine Code: XL Evolution 👋 Introduction Market Position Target Audience: DIY enthusiasts and experienced mechanics Competitive Analysis Advantage Over Paper: Cost-effective, convenient digital format, selective printing Key Features Content Richness: Hundreds of pages with photos and illustrations Accessibility: Instant download, no expiry dates Value Proposition Cost Saving: Reduces reliance on costly mechanic labor 📋 Manual Details Coverage Areas Primary Coverage: Full Service and Repair Styles Covered: All Styles Page Count Estimated Pages: Hundreds Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Digital Compatibility: Windows, Mac, Smartphones, Tablets, Web Browser 📖 Manual Coverage Systems Covered Engine: Complete Engine Systems, Lubrication, Cooling Fuel System: Fuel System Components and Service Drivetrain: Clutch, Drive, Transmission, Final Drive Chassis: Frame, Steering, Suspension, Wheels, Tires, Brakes Electrical: Electrical System, Wiring Diagrams Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements Repair: Component Repair and Replacement, Engine Rebuilds, Transmission Overhauls Troubleshooting: Diagnostic procedures and common issues Disassembly Assembly: Step-by-step instructions for complete disassembly Engine Removal Installation: Covered Electrical System Diagnostics: Covered, including wiring diagrams Technical Depth Depth: Comprehensive factory-level detail 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on source scan quality) Print Quality Printability: Fully Printable (user selectable pages) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Software Requirements Reader: Adobe PDF Reader (Free) Compression: Winzip (Free) ⚙️ Engine Specifications Primary Engine Engine Family: Evolution V-Twin Displacement: 1200cc (73.4 cubic inches) Configuration: Air-cooled, 45-degree V-twin Bore X Stroke: 88.8 mm x 96.8 mm (3.496 in x 3.811 in) - Typical for Evolution 1200 Compression Ratio: 9.7:1 (Typical for 2004 XL1200C) Fuel System Fuel Delivery: Carburetor (likely Keihin CV 40mm) Fuel Type: Unleaded Gasoline (91 octane recommended) Ignition System Ignition Type: Electronic Ignition Engine Lubrication System Oil Capacity: Approximately 3.0 US quarts (2.8 liters) with filter change Oil Type: Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG) 🔧 Transmission Standard Type: 5-speed Constant Mesh Primary Drive: Duplex Chain Final Drive: Belt Drive Features Clutch Type: Wet, multi-plate 📐 Dimensions Exterior Length: Approximately 90.5 inches (2299 mm) Width: Approximately 32.1 inches (815 mm) Height: Approximately 47.2 inches (1199 mm) Weights Dry Weight: Approximately 557 lbs (253 kg) Gvwr: Not specified in product info, but typically around 900-1000 lbs for Sportsters Wheels Tires Front Wheel Size: 16-inch Rear Wheel Size: 15-inch Front Tire Size: 130/90-16 67H Rear Tire Size: 150/80B16 77H 🛡️ Safety Features Ratings Crash Test Results: N/A for motorcycles in traditional automotive sense Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Passive Features Lighting: Headlight, Taillight, Turn Signals 💡 Technology Features Infotainment Audio System: N/A (Typically aftermarket add-on) Driver Assistance ABS: Not standard on 2004 models 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles or 6 months (consult manual for specific details) Primary Chain Tensioner: Check and adjust as needed (interval varies) Spark Plugs: Replace every 10,000-15,000 miles (check manual) Belt Drive: Inspect for wear and tension at regular intervals Fluid Specifications Brake Fluid: DOT 4 Transmission Fluid: Harley-Davidson Formula+ (or SAE 50) Known Issues Carburetor Tuning: CV carburetors can require periodic adjustment for optimal performance, especially after modifications. Primary Chain Tensioner: Automatic tensioner can wear out, leading to noise and potential primary chain issues if not addressed. Cam Chain Tensioners: Early models used plastic tensioners that could wear; 2004 models may have improved but are still a common area of inspection. 📚 Vehicle History Brand Heritage Manufacturer Origin: United States Model Evolution Sportster Lineage: The Sportster line is one of Harley-Davidson's longest-running models, dating back to 1957, known for its sporty character. Xl1200C Custom Positioning: The 'Custom' model typically featured more chrome, custom paint options, and a lower seat height compared to other Sportster variants. Production Manufacturing Location: United States (Milwaukee, Wisconsin) 🏆 Awards & Recognition Recognitions Model Specific Awards: N/A (Product information does not specify)