2004 Harley Davidson Sportster
XL883 | XL883C
| XL1200C |
Four XL Models Feature All-New Chassis and
Redesigned Engines. Blending 47 years of hot
rod tradition with a host of technological updates,
the Harley-Davidson Sportster platform is all
new for 2004. Since it was introduced in 1957
as a raw-boned, highperformance hot rod, the
Sportster has become an icon on the American
road, always evolving yet staying true to its
"The all-new 2004 Sportster artfully blends
beautiful styling and exciting new technical
features, yet retains the character that has
been the soul of the Sportster family since
1957," said Bill Davidson, Harley-Davidson director
of marketing, motorcycle product development.
"This new motorcycle is narrow and agile in
the Sportster tradition, but takes the Sportster
family to a new level of performance and comfort."
Four Sportster Models for 2004
The 2004 Sportster family includes four models:
the affordable and classic XL 883 Sportster
883, the sleek XL 883C Sportster 883 Custom,
the powerful XL 1200C Sportster 1200 Custom,
and the new and aggressive XL 1200R Sportster
1200 Roadster. Each is powered by a redesigned
Sportster Evolution powertrain, now rubber-mounted
in a new frame that is 126 percent stiffer than
the previous Sportster frame, and features a
lower seat height than previous Sportster models.
Sixteen colour choices will be available for
2004 Sportster models: including standard, pearl
and two-tone colour schemes. Additionally, more
than 180 Genuine Motor Parts & Accessories are
available for new Sportster models, including
Screamin' Eagle performance parts.
The New Evolution
The XL Evolution V-Twin, that has powered the
Sportster since 1986, is completely redesigned
for 2004. The engine retains its traditional
45-degree cylinders, and the bore and stroke
of the two engine models is unchanged, at 3.0
inches x 3.8 inches for the XL Evolution 883
and 3.5 inches x 3.8 inches for the XL Evolution
To enhance engine cooling, new cylinders and
heads have larger fins while new oil jets are
directed at the bottom of both pistons. New
pistons have an improved high-speed ring pack
designed to help extend upper-end life. Lighter
pistons and connecting rods boost the Evolution
1200 redline from 5500 rpm to 6000 rpm. Many
engine covers and gaskets have been changed
to improve sealing. A new timing system uses
the flywheel to determine engine timing, reducing
engine complexity and enhancing calibration
and spark delivery. The traditional XL Evolution
timing cover is retained for styling.
The XL Evolution 1200 engine has high-flow
cylinder heads with an oil drainback feature.
The XL Evolution 1200 engine is also fitted
with highperformance cams for enhanced torque
output. Compression ratio is 10.0:1. The XL
Evolution engines have also been restyled, with
a new look for the primary, sprocket and derby
covers and a new shape for the classic, oval
air cleaner cover. New two-piece rocker box
covers set the new Evolution engines apart.
The exhaust cross-over pipe is now hidden behind
the mufflers to provide an uninhibited view
of this beautiful engine.
The XL Evolution 883 engine is rated at 53
peak horsepower at 6000 rpm and 69 NM of torque
at 4400 rpm. The XL Evolution 1200 engine is
rated at 70 peak horsepower at 6000 rpm and
93 NM of torque at 3300 rpm, an increase of
more than 15 percent over the previous XL Evolution
1200 engine. Rubber-Mounted for Comfort.
The updated XL Evolution engines are mated
to a new frame with rubber engine mounts replacing
the traditional Sportster rigid mounts. Rubber
engine mounts isolate the rider from engine
vibration at all speeds, improving longdistance
comfort. The new twin-cradle, steel frame and
swingarm were designed to deliver precise handling.
Three tie-links also connect the engine to the
frame. The result is a new frame and powertrain
combination that's 126 percent stiffer than
that of previous Sportster models.
The new frame locates both the battery and
oil tank under the seat, with symmetrical covers
on each side, a change that enhances styling
and also permits a more comfortable riding position.
The new oil tank has a pushbutton dipstick in
a new location. In addition, the frame now incorporates
a cylinder steering head lock. Seat height on
Sportster Custom models is now just 26.3 inches,
almost an inch lower than the seat on the 2003
883 Hugger model.
The Sportster 883 Custom and Sportster 1200
Custom models feature a new 17 litres fuel tank
that offers more range and yet retains the "peanut"
profile of the traditional 12.5 litre Sportster
tank. All 2004 Sportster models also have a
wider rear fender covering a new 150mm rear
tyre that replaces the 130mm rear tyre used
on the 2003 models. A new braking system reduces
initial lever effort and includes standard single
front and rear disc brakes on all models except
the Sportster 1200 Roadster, which has dual
front disc brakes. New handgrips on all models
are 28.7mm diameter compared to 31.75mm on previous
models, to enhance comfort and to reduce the
reach to hand controls. Finally, all new Sportster
models are equipped with a serial BUStype electrical
system making the Harley-Davidson security systems
available as an option on all 2004 Sportsters.