🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200R Sportster Roadster Year: 2004 Type: Motorcycle Codes Engine Family: Evolution (Evo) 👋 Introduction Market Position Positioning: A critical resource for owners of the Harley-Davidson XL1200R Sportster Roadster, providing factory-level expertise for maintenance and repair. Competitive Analysis Differentiation: Distinguished as an 'Actual Genuine Repair Service Factory Manual,' not a third-party publication, ensuring accuracy and completeness. Key Features Features: Provides step-by-step instructions, detailed illustrations, troubleshooting guides, and common fixes, empowering owners to perform their own servicing. 📋 Manual Details Coverage Areas Areas Covered: General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams, Troubleshooting Page Count Estimated Pages: Hundreds (specific count not provided, but indicative of comprehensive coverage) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage including diagnostics, repair, rebuild, and management systems. Fuel System: Comprehensive diagnostics and repair procedures for fuel delivery and management. Electrical System: In-depth troubleshooting, repair procedures, and detailed wiring diagrams. Chassis: Includes frame, suspension, steering, wheels, and tires. Drivetrain: Covers clutch, transmission, final drive, and drive systems. Procedures Included Maintenance: Step-by-step guides for routine servicing and preventative maintenance. Troubleshooting: Advanced troubleshooting guide with techniques used by factory technicians. Repair: Detailed repair procedures for all major components and systems. Diagnostics: Guidance on diagnosing engine fault symptoms and other mechanical issues. Technical Depth Depth: Complete factory-level technical information for maintenance, repair, and rebuilding. 📊 Manual Specifications File Format Format: PDF Compatibility: Compatible with all PC-based Windows operating systems and Mac. Print Quality Printability: Printable without restriction; individual pages or entire manual. Resolution: High resolution Binding Type Binding: Digital (Downloadable PDF), printable for physical binding. Paper Type Paper Type: N/A (Digital format) Requirements Software: Adobe PDF Reader required. ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-twin Displacement: 1200cc (73.4 cubic inches) Bore X Stroke: 3.496 in. x 3.812 in. (88.8 mm x 96.8 mm) Compression Ratio: 9.0:1 (typical for this era) Performance Horsepower Est: Approximately 65-70 HP (est. at crank, varies by dyno and specific configuration) Torque Est: Approximately 70-75 ft-lbs (est. at crank, varies by dyno and specific configuration) Fuel System Fuel Delivery: Fuel Injection (ESPFI - Electronic Sequential Port Fuel Injection) Carburetor Variant Note: While this manual is for the EFI model, historical Sportster Roadster variants also utilized carburetors; this manual focuses on EFI. Ignition Ignition System: Electronic Ignition Lubrication Oil System: Dry Sump with oil tank 🔧 Transmission Standard Transmission Type: 5-speed Manual Clutch Type: Wet, multi-plate Features Drive Type: Primary Drive: Duplex chain; Final Drive: Belt 📐 Dimensions Exterior Length: 88.9 in. (2258.1 mm) Width: 33.5 in. (850.9 mm) Height: 46.5 in. (1181.1 mm) Weights Dry Weight Est: 547 lbs (248 kg) Wet Weight Est: 575 lbs (261 kg) (approx. with fluids) Other Wheelbase: 60.0 in. (1524.0 mm) Ground Clearance: 4.4 in. (111.8 mm) Seat Height: 29.5 in. (749.3 mm) 🛡️ Safety Features Ratings Crash Test Ratings: Motorcycles are not subjected to standardized automotive crash test ratings like cars. Safety is assessed through design and rider input. Active Features Braking System: Dual disc front brakes, single disc rear brake. Passive Features Frame Construction: Steel, welded backbone frame with steel tubing. 💡 Technology Features Infotainment Infotainment System: Factory infotainment systems were minimal on this model; typically featuring analog speedometer, tachometer, and indicator lights. Aftermarket audio systems are common upgrades. Driver Assistance Driver Assistance Features: No electronic driver assistance features like ABS or traction control were standard on this model in 2004. Connectivity Connectivity: No integrated smartphone connectivity or Bluetooth features. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 miles or 6 months, refer to specific manual for exact intervals. Primary Chain Adjustment: Recommended at 1,000 mile intervals or as needed based on play. Spark Plug Replacement: Refer to manual, typically around 10,000-15,000 miles, depending on plug type. Fluid Specifications Engine Oil Type: Harley-Davidson V-Twin 20W-50 Synthetic (or equivalent meeting H-D specification). Primary Chain Case Oil: Harley-Davidson primary chain case oil or H-D Formula+ Transmission & Primary Chain Case Lubricant (or equivalent). Brake Fluid Type: DOT 4 Brake Fluid. Transmission Oil Type: H-D Formula+ Transmission & Primary Chain Case Lubricant (or equivalent). Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended). Known Issues Common Wear Items: Clutch plates, belt tensioners, wheel bearings, brake pads, and fork seals are common wear items requiring periodic inspection and replacement. Electrical Gremlins: As with many motorcycles of this era, occasional electrical connection issues or sensor failures can occur, which this manual's wiring diagrams are crucial for addressing. 📚 Vehicle History Brand Heritage Brand Legacy: Harley-Davidson, founded in 1903, is renowned for its iconic V-twin motorcycles and the Harley-Davidson lifestyle. Model Evolution Sportster Lineage: The Sportster line, introduced in...