The All New 2004 Sportsters

A view of the inner workings of the new Sportster driveline and the new rubber mounts.

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, high-performance 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 26 percent stiffer than the previous Sportster frame, and features a lower seat height than previous Sportster models. Sixteen color choices will be available for 2004 Sportster models including standard, pearl and two-tone color schemes. Additionally, more than 180 Genuine Motor Parts & Accessories are available for new Sportster models, including Screamin’ Eagle performance parts.

Famous American Rider editor, Buzz Buzzelli, road-testing the new Sportster.

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 speed timing, reducing engine complexity and enhancing calibration and spark delivery. The traditional XL Evolution timing cover is retained for styling purposes.

The XL Evolution 1200 engine has high-flow cylinder heads with an oil drain-back feature. The XL Evolution 1200 engine is also fitted with high-performance cams for enhanced torque output. Compression ratio is 9.7:1.

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 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 51 ft. lbs. of torque at 4300 rpm. The XL Evolution 1200 engine is rated at 70 peak horsepower at 6000 rpm and 79 ft. lbs. of torque at 3500 rpm, an increase of more than 15 percent over the previous XL Evolution 1200 engine.

2004 Sportster pushed through mountain corners.

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 long-distance comfort. The new twin-cradle, steel frame and swingarm were designed to deliver precise handling. Three stabilizer-links also connect the engine to the frame. The result is a new frame and powertrain combination that’s 26 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 push-button 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 4.5-gallon fuel tank that offers more range and yet retains the “peanut” profile of the traditional 3.3-gallon Sportster tank. All 2004 Sportster models also have a wider rear fender covering a new 150mm rear tire that replaces the 130mm rear tire 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 1 1/8-inch diameter compared to 1-inch on previous models, to enhance comfort and to reduce the reach to hand controls. Finally, all new Sportster models are equipped with a serial BUS-type electrical system making the Harley-Davidson security systems available as an option on all 2004 Sportsters.

XL 883 Sportster 883

With its redesigned engine and new chassis, the Sportster 883 sets a new standard for middleweight custom motorcycles. The lower seat height (27.3 inches), reduced clutch lever effort and rubber-mounted engine help make the Sportster 883 more comfortable and easier to ride, but its stiffer frame and enhanced brakes mean it still delivers the agile handling that is the heart and soul of a Sportster.

XL 883 Sportster 883 features:
Rubber-mounted XL Evolution 883 engine
Lighter 883 clutch springs reduce lever effort by 25 percent
Silver powder-coated engine with polished covers
Low-rise handlebar
Classic solo seat
Chrome staggered shorty dual exhaust
Mid-mount foot controls
Classic-look 3.3-gallon fuel tank

XL 883C Sportster 883 Custom

The bold new Sportster 883 Custom offers fresh, swept-back styling. The rubber-mounted engine and extra-low seat (just 26.3 inches) make this a bike you can ride all day. The new fuel tank holds 4.5-gallons yet retains the “peanut” profile of the traditional 3.3-gallon Sportster tank. Pull-back handlebars and a new swept-back riser, move the grips 1.5 inches further back, while new foot controls are also 1.5 inches back, compared to the 2003 model.

XL 883C Sportster 883 Custom features:
Rubber-mounted XL Evolution 883 engine
Lighter 883 clutch springs reduce lever effort by 25 percent
Silver powder-coated engine and covers
Chrome pull-back handlebar riser
Laced front wheel, disc rear wheel
One-piece, two-up seat
Forward foot controls
New-look 4.5-gallon fuel tank

XL 1200R Sportster 1200 Roadster

A new model designed to pay tribute to the no-nonsense style and performance of the original 1957 XL Sportster, the Sportster 1200 Roadster offers wide, polished handlebars, 13-spoke wheels and a timeless fuel tank design. Dual front disc brakes and tachometer are standard.

XL 1200R Sportster 1200 Roadster features:
Rubber-mounted XL Evolution 1200 engine
High-compression, high-flow cylinder heads
High-performance cams
Silver powder-coated engine and covers with black powder-coated cylinders and heads
Triple-disc brakes
Tachometer
13-spoke aluminum wheels
Wide polished handlebar
Classic-look 3.3-gallon fuel tank

XL 1200C Sportster 1200 Custom

Long, lean and mean, the Sportster 1200 Custom was built to rule the street. The new 4.5-gallon fuel tank retains the classic “peanut” profile, and the new riser and pull-back handlebars lend a swept-back style. Handlebars and foot controls are 1.5 inches further back for 2004. The new Evolution 1200 rubber-mounted engine makes it more comfortable; a generous dose of chrome makes it stunning.