2004 Harley-Davidson XL1200C

Owner complaints

Latest complaints

• Mar 27, 2006NJ3,000 mi
  Engine and engine cooling › Engine › Gasoline › Belts and associated pulleys

  I heard a tapping sound while riding my motorcycle. A cracked upper belt cover/guard was detected. No injury occurred but the cover could have gotten caught in the belt causing a serious injury to rider. The welding on the guard was cracked. *jb

• Sep 27, 2004OH
  Engine and engine cooling
  Battery cover on 2004 harley-davidson 1200 custom sportster has blown off twice while traveling down interstate highway. First time a car behind me swerved but still ran over cover. Second time a friend on his motorcycle behind me was nearly hit by cover. I allied harley-davidson customer service…

  Battery cover on 2004 harley-davidson 1200 custom sportster has blown off twice while traveling down interstate highway. First time a car behind me swerved but still ran over cover. Second time a friend on his motorcycle behind me was nearly hit by cover. I allied harley-davidson customer service and rep was aware of problem and gave me a reference number to give my dealer. My dealer was unaware of problem with the 2004 sportster and I wonder why no recall on this issue. *ak

Service bulletins

Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.

• 11008736SERVICE BULLETIN M1555 (REV E): BATTERY WARRANTY GUIDELINES. PURPOSE: Revision E. Added: Added procedures for the DCA-8000 E Battery Tester.* Updated: All sections. This bulletin informs the dealership network that Harley-Davidson has provided guidelines for battery warranty.
• 11007544SERVICE BULLETIN M1490 (V 24.8.8): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.8.8. Release Date: Week of August 5, 2024. New Features for Harley-Davidson vehicles: Advanced Module Replace for 2021 and later Revolution Max; 2023 and later CVO Touring; and 2024 Street Glide (FLHX), Road Glide (FLTRX). New Features for LiveWire vehicles: Updated calibrations for 2024 S2DM EV1/ EV6; 2024 S2MH EV1; and 2024 S2DM, S2MH. Changes: Added Hand Control Module (HCM) (Part No. 71500522A and 71500536A) for reflash support.
• 11005514GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1158: OIL FILTER PACKAGING AND CASE QUANTITY UPDATE. PURPOSE: To inform dealerships that Harley-Davidson has made updates to oil filters including new part numbers, packaging design, and bulk case quantity changes.
• 11001293SERVICE BULLETIN M1490 (V 24.6.4): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: Revision. This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.6.4. Release Date: Week of May 1, 2024. New Features for LiveWire S2DM and S2MH, 2024 Revolution Max, and 2024 Touring.
• 10248401GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1146: 68193-95 BULB WEDGE, FENDER TIP LAMP. Purpose: To inform dealers of an issue with the bulb wire terminals not being to specification. The light bulbs were used in numerous front and rear fender tip light assemblies for domestic and international applications.
• 10139399TECH ARTICLE TA0023: TA0023: Crankshaft Rod Bearing. Purpose: Technicians have been falsely identifying connecting rod bearings as failed due to a perception of resistance as the rods are rotated. The clearance of the Twin Cam and Milwaukee-Eight crank pin bearings are maintained to a very tight range. This optimizes performance and maintains low mechanical noise in operation. The connecting rod bore can also distort slightly in operation due to stress relaxation. As a result, bearing clearance decreases due to the contact zone broadening and the load being distributed over more rollers. The combination of a bore being slightly out of round and reduced bearing clearance can result in varying degrees of resistance through the range of motion. Axial clearance is also tightly controlled for proper alignment. For these reasons, zones of resistance can be found when the connecting rods are rotated by hand through their range of motion. Resistance during rod motion, by itself, is not an indication of a performance or durability concern.
• 10090280This document will outline inspection and measurement procedures for gerotor style oil pumps. It provides inspection procedures only without specifications.
• 10017979Inner rocker covers.

Every Harley-Davidson XL1200C model year

Bars are owner complaints, dots mark years with recalls. Select a year to open its report.