Since it was introduced in 1957 as a raw-boned, high performance hot rod, the Sportster has become an icon on the American road. But while the last of the 883 Sportsters looked cool, they needed a bit more oomph.
Now Harley has come up with a brand new rubber-mounted 1200cc Evolution powertrain, a frame that is claimed to be 126% stiffer than the previous Sportster frame, and even lowered the seat by 25mm or one old-fashioned inch. The XL1200R is a bike that merits the "sport" tag.
The XL Evolution V-Twin that has powered the Sportster since 1986 has been completely redesigned for 2004. The engine retains its traditional 45-degree cylinders and the bore and stroke of the two engine sizes 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.
For better engine cooling, the cylinders and heads have larger fins while new oil jets are directed at the bottom of both pistons. The pistons have an improved high-speed ring pack designed to help extend upper-end life. Lighter pistons and conrods boost the Evolution 1200 redline from 5500 rpm to 6000 rpm. Many engine covers and gaskets have been changed to stop oil leaks.
A new timing system uses the flywheel to determine engine timing; reducing mechanical complexity and enhancing spark delivery. The traditional XL Evolution timing cover stays - the styling is part of Sportster heritage. The XL Evolution 1200 engine is also fitted with high performance cams for better torque. Compression ratio is 10.0:1.
New two-piece rocker box covers set the new Evolution engines apart. The exhaust crossover pipe is now hidden behind the mufflers to provide an uninhibited view of this gorgeous engine.
The XL Evolution 883 engine is rated at 53bhp at 6000rpm and 69 NM of torque at 4400 rpm. But the 1200 pumps out a claimed 70bhp 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.
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 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. The 2004 models now get a 150mm rear wheel and wider rear mudguard, and a new streamlined air cleaner cover.
The Sportster 1200 Custom models feature a new 17-litre fuel tank that retains the "peanut" profile of the traditional 12.5 litre tank. 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.
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.
The XL 1200R Sportster pays tribute to the no-nonsense style and performance of the original 1957 XL Sportster, with wide, polished handlebars, 13-spoke wheels and a classic fuel tank design. Dual front disc brakes and tachometer are standard.
All 2004 Harleys will be covered by a two-year warranty and most service intervals have been extended from 2500 miles to 5000 miles.
