04 HD Sportster Roadster question

[analog kid]

Hi everyone,
Shortly, I will be going to see an 04 Sportster 1200 Roadster for sale. I'm starting my search on WG for previous threads, but I'm wondering about the drive belt. Was there a recommended replacement interval or is it on condition? I suspect this one is original and should I factor in belt replacement cost? Parts only, labour will be mine.

This bike has been sitting for at least a year, possibly 2. Belongs to a neighbour and is now part of her estate. So battery required of course, possibly tires and the usual mtc items. I've not seen it recently but rode it once in the past. I liked it. I also knew the owner and know a bit about its maintenance history.
Approx 48000 km / 30000 miles. That's not high mileage to me

It's the first year of rubber mounts and carbed.  Any problems stand out on this model?
I've owned a belt drive bike before and have no problem with it.
Thanks.

[fotoguzzi]

my Buell belt was called lifetime, meaing if it breaks replace it, I did it preemptively at 20k. Belt>chain.

[Shorty]

1200R gotta be one of the nicest looking HDs in recent years. Unless you damage it somehow, the belt is a long term item. Not much to go wrong on a rubber mount Sporty, if the PO didn't modify it too much. I had a 2004 , and my complaints were fuel consumption, top heavy handling, and a vibration I could not get used to right in the sweet spot of 60-80 mph. Other Roadster owners have not shared my experience. I think they will be sought after in years to come. Enjoy it.   

[SemperVee]

   I would own another sporty in a minute.  That or the 2012 sports model.

[arveno]

I am not sure but if i remember correctly HD recommend to replace the belt at 75 K miles ? ( as preventive maintenance but it could last 100 k and more. )

I will not be too concern about the belt thought , just inspect it and if the are no cracks  , i would just ride it.

if the bike was properly stored it should last forever....

[Kev m]

I could be wrong and I'll check the maintenance schedules tomorrow to be sure, but I don't recall ever seeing a belt replacement interval.

If not overtightened, contaminated by oil, or cut by a stone, they should last more than a decade or 100k easily.

Anyway the 04-06 rubbermount 1200R bikes are fantastic models. They are overcooled, under-stressed, and generally very hearty.

My buddy Chris has completed two IBR's on his 06 1200R, and that was AFTER it already had 200k+ miles on it.

Granted, he did replace the engine after 225k or something like that, but it seems it was likely because of a botched rebuild which was undertaken only because of a single roller bearing that was failing.

Anyway if you pick it up just do some basic maintenance (fluid, filters, battery if needed) and assess from there.

Oh, btw, on mine I went down a size on the rear tire 150-->140, but up a size on the front 100-->110.

The rear quickened turn in, the front just felt better balanced.

Good luck.

[yogidozer]

lots of info on sportys here http://www.xlforum.net/vbportal/forums/index.php

[analog kid]

I will not be too concern about the belt thought , just inspect it and if the are no cracks  , i would just ride it.

if the bike was properly stored it should last forever....

Yeah, I was once the second set of eyes on a 97 Heritage a friend was interested in. I was all over the belt for condition, which was good. Too bad I didn't notice the rear wheel was at its adjustment limit. D'oh!
But he bought it and the belt never gave him trouble, so I'm not overly concerned.

The seller has not responded yet, so no inspection.

Some details:
I asked if they kept the stock pipes which I will reinstall in place of the V&H 'mufflers' the owner put on. 
Don't know if the jetting was messed with.
Has a Mustang seat which the PO said really increased her ride time from the stocker.
HD quick release windscreen
Heated grips
Soft sidebags
Crashbars......
Was owned by a first time rider, so it's been driveway dropped a few times. When I rode it, the handlebars were slightly bent, I assume from a drop. The owner had not noticed.

Thinking about it now, the bike might turn out to be a bit ratty. Not abused, but not cosseted either. It was ridden (slowly) and basically maintained, but I never did see her wash it.

[analog kid]

If not overtightened, contaminated by oil, or cut by a stone, they should last more than a decade or 100k easily.

Oh, btw, on mine I went down a size on the rear tire 150-->140, but up a size on the front 100-->110.

Cue my Mr. Burns voice: Eeeeeeeeexxxxxxxcee ellent
Tire sizes noted KevM.
I will be buying tires for it.....2/32 - 3/32 tread remaining on the Dunlop D401s.

Bought it this afternoon, but have not ridden it yet due to licensing & no insurance.

Very very fair price, Mustang seat, leather saddlebags (maker unknown), HD windscreen, heated grips, the owner threw in a bike lift - which I have already, but can sell it to put into tires. Battery checks ok, has been on a Tender while stored.
Per the owners manual, it's time for its 48000 km maintenance check. Most of that stuff I do anyways when buying a new bike. HD says it's time to replace the swing arm bearings, that's the only unexpected maintenance item, but no big deal.

Has been maintained but not cosseted. One broken pipe mount is all I've found so far.
Needs mufflers. The V&H mufflers have nothing by way of baffling. I'm not interested in cracking the neighbors windows upon start.
 Carb throat is black. I don't know if it was rejetted when the stock mufflers were replaced. Either way , it's running rich. Will get into the carb to see what jets are in there. Plugs are black too.

One minor blister on top of fuel tank; looks like a brake fluid drip when refilling ft. brake reservoir.
As much as I make (made ?) fun of Harley riders and their polishing obsession, this afternoon I mentally noted that I have a can of Chrome cleaner in storage and......will be using it.

I don't have a picture host, so can't post a pic yet.

Thanks all for posting info , I'm sure I'll enjoy the ride!

[fotoguzzi]

on the reply page lower left, you can use "add image to post" and use a pic right from your computer- no host needed.

[Shorty]

Stock mufflers are pretty cheap on Flea bay. Local dealer might have a stack of them as well.    if not already equipped, one of these extended mixture needles is a nice addition to the Sporty. Allows you to adlust mixture without needing skinny fingers and a tiny screwdriver. You may need to remove the blanking plug on the mixture screw.

https://www.jpcycles.com/2004-harley-davidson-sportster-1200-roadster-xl1200r/carburetor-jets-and-needles/cv-performance

[Kev m]

Sweet. Let me know if you need any tech info.

[analog kid]

on the reply page lower left, you can use "add image to post" and use a pic right from your computer- no host

Ah, well then:




And unlike the others, no one will ask me : "who makes that?"

[blackcat]

Good luck with the bike, very nice looking.

I had a Sportster(89?) for a few years, always enjoyed it and I assume the newer models are way better than mine. 

[SmokinJoe]

I like mine.

 
Mine is 07 883r so FI. Added bigger tank, different seat as you see. On the carb model i'd hope it was stored properly, if not you may have some issues that are hard to overcome without a replacement. Everything else should be fine. The one I have sat for a couple of years as well with no issues except battery and hard/aged tires. But good luck may prevail. This pic is at the end of a 500 mile day and was still feeling good. So how much better does it get?

[Shorty]

My 04 1200R. Long gone. 

[Muzz]

My son owns a 2002 Sporty, his 4th. (He will only have the Sporty in the HD range) He carries a spare belt. The advantage with the Sporty over the big blocks evidently is that you do not have to disassemble the clutch to fit a new belt. He intends to ride it until it goes bang, then replace it.

The fact that he carries a spare means it will never go bang....

[dxhall]

Kev - what's the appeal of 2004 - 2006 bikes?  I know that '04  was the first year of rubber engine mounts, but what changed with the '07 models?

[Kev m]

Kev - what's the appeal of 2004 - 2006 bikes?  I know that '04  was the first year of rubber engine mounts, but what changed with the '07 models?

04-06 were carbureted but they contained the greater cooling fin surface area and new piston oil jets etc. that were designed to keep the soon to come hotter running EFI motors cool. So they are very robust.

The 07 was the first year for EFI.

[dxhall]

There's an '05 for sale near me, 4000 miles, $4500 asking price.  Thoughts?

[Kev m]

There's an '05 for sale near me, 4000 miles, $4500 asking price.  Thoughts?

If you like it then I think it's a decent bike for the money (though I bet you could get it under $4k).

I always compared my 07 to my Jackal in a lot of good ways.

As a matter of fact I rode my 07 today because I was missing it.

Let me know if you have specific questions. And if you ride it what you think of it.

[davevv]

Congratulations on the purchase.  They are great bikes.  I bought my '04 Roadster a little over four years ago, which means I've owned it longer than any other bike I've had in 56 years of riding.  Finally upgraded the suspension with Progressive 444 rear shocks, Intiminators in the forks, and a fork brace this year.  Better than ever!

[MMRanch]

Ive had two Harleys , both Sporters , one a 2004 -1200 Roadster ,  Its' fast and a little top heavy and vibrates in the sweet 70-80 mph range .   

The second one I still got , a 2007 883 , not so fast (but fast enough) , a little top heavy , and velvety smooth.   

apparently HD built the 883 and got it perfect , then as an after thought ...  ... put the bigger pistons in it .   Well , its "good" but no longer "perfect" .
Plan on using 93 octane in your 1200 ... 

No , that's not the original paint   


If I ever buy another HD , it will be a : 2004 -2006 --- 883 .   

 

[Moto]

If the left (port) side of the Sportster Roadster's motor looked like the right side, I would be dying to get one.

As it is, I can't imagine how you could turn left on it, with that clutch casing sticking out like it is.

I guess you could circle around the block to your right and make a left turn that way.

Moto

[Kev m]

Two things:

* It shouldn't need 93, it's only spec'd for 91.

* The clutch doesn't stick out very far. The Sportster is a narrow, unitized crankcase design.

[Rough Edge racing]

   Talking to Harley guys it seemd that the belt life is very different for each bike and each rider...What I do hear is if a small stone gets in the belt ,failure is soon to happen.....In my opinion, the stock Sportster dual pipes should be thrown away and the bike fitted with a proper two into one exhaust like a Buell, but not exactly the same obviously...That and on proper air cleaner on a carburated Sportster is good for 15 HP without an increase in noise....From my experience on a Buell, the Mikuni 42 MM flatslide was also an improvement in performance and fuel mileage compared to the stock  CV carb...The Buell has slightly higher compression and had no problem with 91 octane non ethanol gas...

[Kev m]

   Talking to Harley guys it seemd that the belt life is very different for each bike and each rider...

I don't know that I'd say it's very different for each bike, it really depends on 3 things:

1. Use - lots of dirt and gravel means you'll pick up a stone at some point, and if not found, eventually a failure.
2. Adjustment - too tight is not right.
3. Oil/Chemicals - contamination will eventually lead to failure.

I think it's way more common that owners never replace a belt, and there are plenty that make it past 100k miles.

I do have a little bit of stone damage on my current belt at 30k miles, but no plans to replace it.

[Rough Edge racing]

I don't know that I'd say it's very different for each bike, it really depends on 3 things:

1. Use - lots of dirt and gravel means you'll pick up a stone at some point, and if not found, eventually a failure.
2. Adjustment - too tight is not right.
3. Oil/Chemicals - contamination will eventually lead to failure.

I think it's way more common that owners never replace a belt, and there are plenty that make it past 100k miles.

I do have a little bit of stone damage on my current belt at 30k miles, but no plans to replace it.

  Yes on the too tight....On the tube frame Buells the factory belt tightness recommendation leads to early belt  and transmission high gear bearing failure...The proper adjustment is quite loose, about two inches easy play on the top run with the rider seated......A Sportster has different swingarm motion than a Buell but the loose belt is better than tight...

[Kev m]

  Yes on the too tight....On the tube frame Buells the factory belt tightness recommendation leads to early belt  and transmission high gear bearing failure...The proper adjustment is quite loose, about two inches easy play on the top run with the rider seated......A Sportster has different swingarm motion than a Buell but the loose belt is better than tight...

 

Same thing on Sportys (and probably most Harleys), i.e. the factory spec is tight.

Also early on in the rubbermounts some guys who were running them too tight (at factory spec or tighter) were getting some effect in the suspension from it. Some guys took off the rear shocks and moved the swing arm through the arc and found just how tight it was getting at the tightest point in the arc and realized they needed to loosen them up. This eliminated any effect on the suspension from the belt binding at that point in the arc.

Basically the taller the suspension and longer the arc the looser the belt needs to be (as seen in the specs) and then add another couple of 1/8th's for good measure.

 

[Tom H]

Looks like I need to loosen the belt on my Street Bob. I adjusted it per the book with a belt tension tool. Don't know how accurate I was though.

Does anyone know what #'s the belt should be, or how many inches it should move with the bike in a front wheel chock and no rider weight? I would need to measure from below where my sight hole is.

I ask because sometimes on rough pavement the bike almost has a vibrationy type feel while the suspension is working. Maybe the belt is too tight?

Thank you,
Tom