2004 Harley Davidson Sportster Range

XL883 | XL883C | XL1200 | XL1200C | XL1200R

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 roots.

"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 1200.

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.