20 Most Recent 2004 Harley Davidson XL 1200 C Sportster Custom Questions & Answers


Hi, Ralph, the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts enquiry.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2004 Harley... | Answered on Jul 17, 2019


Hi, Brainstorm I'm guessing 5/16" for more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day. http://sportsterpedia.com/doku.php/sportster_history:99xx-01
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2004 Harley... | Answered on Jul 08, 2019


Hi, Dave for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
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2004 Harley... | Answered on Jun 08, 2019


Hi, Damaso for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
How To Repleace Starter Relay Sportster Hugger 1995
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2004 Harley... | Answered on Sep 13, 2018


under panel on left side near seat

2004 Harley... | Answered on Sep 11, 2018


Hi, Keith before testing any electrical component in the Starting Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Engine Run Switch is "FAULTY" or corroded.
4. Check the battery terminals for damage or corrosion check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter.
5. Bank angle sensor needs a reset or is faulty.
6. FOB battery low or dead.
7. Faulty ignition switch.
8. Faulty starter button.
9. Faulty kickstand, clutch, neutral safety switch.
10. Security alarm needs a reset.
11. Starter relay, solenoid, starter motor or circuit wiring faulty.
12. Starter armature or field coils have failed.
13. Main fuse or circuit breaker may be blown or faulty.
14. Faulty ignition relay.
15. The electric starter is working but starter clutch has failed.
16. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
Harley Sportster Won Start or Turn Over 2007 2008 Models Harley Davidson 2005 Sportster Service Manual
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2004 Harley... | Answered on Mar 12, 2018


Hi, Kimber for this scenario you will need your service, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://serviceinfo.harley-davidson.com/sip/content/document/view?id=5530
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2004 Harley... | Answered on Sep 27, 2017


Hi, Melody you may have a starter clutch/Bendix going south on you and I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
1. Bearings---SCREECH
2. Belts---CHIRP
3. Brake Rotors---BUZZ
4. Chains---RATTLE
5. Clutches---CHATTER
6. Cylinders---PING
7. Fairing Panels---WHISTLE
8. Fronk Forks---Plunk
9. Gears---WHINE
10. Head Gasket---HISS
11. Hydraulic Lifters---TAP
12. Pistons---SLAP
13. Rear Shocks---SQUEAK
14. Shifting Trans---CLUNK
15. Solid Lifters---TICK
16. Starters---CLICK
17. Connecting Rods Go---KNOCK-KNOCK---who's there, it's me "*****"
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
05 1200 starter making noise
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2004 Harley... | Answered on Jun 24, 2017


To change the fork oil, look down on the lower part of each fork leg just above the axle on the backside of each leg and you'll find an Allen plug or small screw. Take this screw out, hold the front brake and push down on the front forks. The fork oil will come out of the tube. Do both sides at the same time. Once you get the oil out of them, reinstall the drain plug. Then, take the large hex cap on ONE TUBE AT THE TIME and pour the correct amount of the correct fork oil into each tube. There is a specific amount of oil that must be poured into each leg. Since you simply drained your forks instead of disassembling them, you should use what is known as the "Wet" quantity of oil. I'm pretty sure your bike takes 9.0 ounces of oil in each leg. Call your local dealer and they'll tell you how much oil to put in. Your bike came from the factory with "Type E" oil in the forks. The viscosity of the oil determines the dampening effect of the forks. Heavier oil will stiffen the front forks, a lighter viscosity of oil will make the front end softer. You can check the Internet for fork oils and they should give you a comparison of what weight oil is equivalent to "Type E" oil. I think PJ 1's 30 weight oil is the same as type E Harley oil. Use only "fork oil" in your front forks as it has special "anti-foaming" agents in it. If the oil foams up, you'll lose the dampening effect in your forks.

Good Luck
steve

2004 Harley... | Answered on Apr 19, 2016


I would guess that your shifter pawl has broken. This is the most likely cause of the problem. It's not a major problem but it is aggravating to repair.

To replace the shifter pawl, you'll have to remove the outer primary cover, the engine sprocket, and the clutch assembly. With this out of the way, the shifter pawl is easily accessed. This can be done with basic hand tools and a good torque wrench that will torque in both the right hand and left hand rotation directions. I would advise the purchase of a service manual because there is an alignment that must be made and a picture is the best way to do it. I'm afraid that I can't send that picture. Besides, if you fix your bike using the service manual, the book just paid for itself.

Good Luck
Steve

2004 Harley... | Answered on Apr 17, 2016


Hi Robert, it should be noted that in order to "PROPERLY" diagnosis any electric starter issue it is "IMPERATIVE" that you begin with a fully charged battery 12.5 volts or better and be able to pass a proper load test, and the usual suspects are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, 12.5 volts or better,to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid has dropped more than 1/2 volt.
4. With a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 8-9 volts.
If a lower voltage is produced a proper battery load test should be performed with a load tester to validate battery integrity or battery replacement.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohm-meter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buy a new one.
For more information about your issue, please visit the websites below, and for specific information or questions, please feel free to contact me at [email protected] Good luck and have a nice day.
HARLEY STARTER CLICKING SOUND PROBLEM HELP sporster 883 harley davidson
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2004 Harley... | Answered on Dec 11, 2015


The speed sensor is usually on the rear of the engine back near the front belt pulley on the right hand side.

Good Luck
Steve

2004 Harley... | Answered on Oct 18, 2015


Hi Robert, it is either behind the tail light lens or under the seat depending on what you are starting with. If you could take a picture of what you are talking about and e-mail it to me, [email protected], I am sure I can point you in the right direction. Gregg

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2004 Harley... | Answered on Aug 16, 2015


Hi Robert, they do not hook up to the battery, instead they are plugged into connectors in the light circuit that eventually end up at the light circuit fuse, for a free wiring diagram, please visit the website below. If you need more information about a specific electrical issue you can reach me at [email protected] Good luck and have nice day. Harley Davidson Wiring Diagrams and Schematics

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2004 Harley... | Answered on Aug 16, 2015


Hi Wlc92357, for more information about your question please visit the website below. Good luck and have nice day.
Delboy Garage Harley Sportster Battery Replacement

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2004 Harley... | Answered on Jun 07, 2015


Hi Anonymous, for more information on your question please visit the websites below and good luck:
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2004 Harley... | Answered on Jun 03, 2015


Hi A82ellis, when you are trying to diagnois anything in the starter circuit you must start with a fully charged battery of 12.5 volts or better and will pass a load test of 9 volts or better while cranking the engine over and the cable connections are clean and tight especially the negative cable at both ends. If you suspect a faulty starter relay just swap it with your horn, brake, or system/fuel pump relay, if the bike starts with no problems replace the bad relay. For more information on your question please visit the websites below and good luck: Set Change Override Transport Harley Security Alarm PIN Code No Key Fob...

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2004 Harley... | Answered on Jun 02, 2015


Hi Daekala, when checking for spark the CKP needs to measure the compression bump in order to send the correct signal to the ICM/ECM so always check for spark with either a third plug grounded or lift the end of the plug boot 1/2 " off one of spark plugs that are in the head. and the usual suspects are:
1. Fuel tank empty
2. Fuel supply valve turned off.
3. Fouled spark plugs.
4. Engine flooded with gasoline as a result of over use of enrichner.
5. Fuel valve or filter clogged.
6. Vacuum hose to automatic fuel supply valve disconnected, leaking, or pinched.
7. Discharged battery, loose or broken battery connections.
8. Loose wire connection at coil, battery or plug between ignition sensor and module.
9. Spark plug cables in bad condition and shorting, spark plug cable connections loose,
or cables connected to wrong cylinders.
10. Ignition timing incorrect due to faulty ignition coil, ignition module, or sensors " Manifold Absolute Pressure" "Camshaft Position Sensor" "Crank Position Sensor" "Brake Apply Sensor
11. Engine lubricant to heavy ( winter operation )
12. Sticking or damaged valves or push rod wrong length.
13. Primary cam sproket spline sheared or missing spacer.
14. Security alarm system not disarming.
For a primary suspect please visit the website below: Good luck
Harley Davidson Sportster error codes and how to access them

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2004 Harley... | Answered on Jun 02, 2015

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