2004 Harley-Davidson XLH Models Service Manual / Electrical Diagnostics Manual

Comprehensive repair and diagnostic coverage for the 2004 Harley-Davidson XLH models, including XL 883, XL 883C, XL 1200C, and XL 1200R. PN 99484-04 & 99495-04.

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Document Details

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Document Number / Seller:
29412 / George Jackson
File Size:
29.34 MB
File Type:
PDF
Language:
English
Pages:
710
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Jun 11, 2025

Models Covered & Key Technical Specifications

2004 Harley-Davidson XLH Models Service & Electrical Diagnostics Manual

Comprehensive Coverage | Service Manual & Electrical Diagnostics Repository

  • Published Technical Data: 710 pages detail comprehensive service procedures and diagnostic flows.
  • Specific Coverage Details: Includes troubleshooting for electrical systems and component repair sections.
  • Integral Diagnostic Information: Addresses starting and charging, instruments, TSM & TSSM, and engine management.
  • Operational System Analysis: Covers chassis, engine, brakes, tires, wheels, and electrical systems.
  • Established Maintenance Schedules: Features detailed maintenance tasks and service intervals for optimal performance.
  • Authorized Component Data: Provides specifications for critical fasteners and system capacities.

Professional Workshop Service Manual & Technical Specifications

2004 Harley-Davidson XLH Service & Electrical Diagnostics Manual: Harley-Davidson XL 883, XL 883C Custom, XL 1200C Custom, XL 1200R Roadster 2004 - Comprehensive Maintenance & Repair Manual Repository

Model-Portfolio: XL 883, XL 883C Custom, XL 1200C Custom, XL 1200R Roadster // Architecture-Focus: Engine, Chassis, Brakes, Electrical, Drivetrain // Procedure-Type: Repair, Maintenance, Diagnostics, Overhaul

Service-Nexus | Technical-Path | Calibration-Spec

|---|---|---| | Routine Maintenance | Suspension Adjustments | Torque Specifications | | Electrical System Diagnostics | Brake System Service | Tire and Wheel Care | | Engine Lubrication | Fuel System Servicing | Clutch and Drive Train | | Frame and Bodywork | Diagnostic Procedures | Component Specifications |

The repository is divided into detailed sections covering all aspects of your 2004 Harley-Davidson XLH Sportster motorcycle. From routine maintenance schedules to in-depth troubleshooting and component overhauls, this manual provides the essential information needed to keep your bike in top condition. It documents the procedures for engine rebuilds, drivetrain specifications, electrical system diagnostics, and brake system service. This manual also includes detailed torque specifications for critical fasteners, ensuring proper assembly and longevity of your motorcycle's components. Engine rebuild procedures are documented for all major engine systems, and drivetrain specifications are addressed in detail. Reassembly procedures are specified for all key components, and service intervals are documented to guide routine maintenance. Component locations are identified for easy reference, providing a comprehensive guide for both novice and experienced mechanics. This manual contains the necessary technical documentation for maintaining and repairing your Harley-Davidson.

FAQ

What are the **required** fluid capacity specifications? keyboard_arrow_down

3.6 quarts (3.4 Liters) is the oil tank capacity for your 2004 Harley-Davidson XLH models, including the filter.

Calculate the **specified** brake fluid type and quantity for caliper service. keyboard_arrow_down

Harley-Davidson D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) is specified for all brake system services, including caliper and master cylinder maintenance.

What **essential** torque values are needed for the front brake caliper mounting bolts? keyboard_arrow_down

28-38 ft-lbs (38.0-51.6 Nm) is the specified torque for the front brake caliper mounting bolts (6) on your 2004 Harley-Davidson XLH models.

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Reviews (3)

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This manual has been a lifesaver for my 2004 Sportster. The detailed diagrams and maintenance schedules are incredibly helpful. Plus, the download process was smooth, and I received my link almost instantly!
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Rated 5 out of 5 stars
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New
I love how comprehensive this manual is. It covers everything from basic maintenance to complex repairs. The support team was quick to respond to my questions via email, which was a huge help!