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5th January 2023
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Biker
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Join Date: Dec 2022
Posts: 4 Sportster/Buell Model: XL883 Sportster/Buell Year: 2004
Reputation: 10

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I have a couple questions regarding a 2004 883 Custom
I just bought the bike in the picture and have a few changes I would like to make but I am unclear about the differences between the 04/05 and everything that follows when it comes to the exhaust system.
The first change I want to make is to swap the forward controls for mid controls, but I was told by the seller that I would have to change the exhaust in order to do that. Looking at the picture is that true?
Most importantly I was also told that buying a new exhaust system for the bike would be a pain in the ass because 04/05 (Rubber mount, carb) bike require different exhaust because it's a rubber mount, but wouldn't that mean that all rubber mount sportsters from 04 forward would use the same system? I don't see why carb vs EFI would matter.
This is the bike.

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5th January 2023
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XL FORUM TEAM MEMBER
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Join Date: Nov 2005
Location: North cental Ohio
Posts: 2,662 Sportster/Buell Model: XL1200C Sportster/Buell Year: 2009 Sportster/Buell Model #2: XL1200L Sportster/Buell Year #2: 2009
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'04 thru about '09 the exhausts are identical. You don't need to change anything to swap the foot controls, either. Straight up, bolt on trade. Your PO may be correct about that exhaust that's on there needing to be changed, tho, to fit the mid controls. Some of the after-market pipes are not compatable with both mids & forwards. I'm only familiar with the stock pipe configuration as I like the look of the tapered mufflers.
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Brian '09 1200C (black of course), 19" front wheel, det. windshield, Sundowner, mini apes, Big Sucker, 12.5" Progressive 412's, Intiminators, Gronk mod
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6th January 2023
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XL FORUM TEAM MEMBER
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Join Date: Dec 2009
Posts: 2,164 Sportster/Buell Model: XL1200R Sportster/Buell Year: 2004
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That looks like a Bassani. I don't remember anything about them not fitting my 04 with mid controls.
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6th January 2023
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Biker
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Join Date: Dec 2022
Posts: 4 Sportster/Buell Model: XL883 Sportster/Buell Year: 2004
Reputation: 10

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Quote:
Originally Posted by XL Ed
That looks like a Bassani. I don't remember anything about them not fitting my 04 with mid controls.
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Thank you for the hint on the exhaust make. I think these are them.
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6th January 2023
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XL FORUM TEAM MEMBER
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Join Date: Nov 2004
Location: jupiter fl
Posts: 2,957 Sportster/Buell Model: 1200C Sportster/Buell Year: 04
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Those pipes don't fit with mid controls.
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04/07 1275 BFH heads Darkhorse XB crank .600 cams S&S 1.725 rockers S&S precision lifters BDL+15% clutch TC88A HSR-45 S&S 3" ac LSR 2-1
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7th January 2023
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XL FORUM TEAM MEMBER
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Join Date: Dec 2009
Posts: 2,164 Sportster/Buell Model: XL1200R Sportster/Buell Year: 2004
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There you go. I stand corrected.
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3rd February 2023
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Flat Track Champion
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Join Date: Jul 2007
Location: the backwoods of N. Pa
Posts: 652 Sportster/Buell Model: xl1200c Sportster/Buell Year: 2005 Other Motorcycle Model: Ducati Monster Other Motorcycle Year: 1995
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EFI pipes just need to have plugs put in the O2 sensor ports. I think Lowbrow and TC Bros both sell the plugs.
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3rd February 2023
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XL FORUM TEAM MEMBER
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Join Date: Aug 2006
Location: Near Philly
Posts: 8,148 Sportster/Buell Model: 1200R Sportster/Buell Year: 2006 Sportster/Buell Model #2: 1200R Sportster/Buell Year #2: 2007 Other Motorcycle Model: Suzuki GT550 Other Motorcycle Year: 1974
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Quote:
Originally Posted by Turbid
I just bought the bike in the picture and have a few changes I would like to make but I am unclear about the differences between the 04/05 and everything that follows when it comes to the exhaust system.
The first change I want to make is to swap the forward controls for mid controls, but I was told by the seller that I would have to change the exhaust in order to do that. Looking at the picture is that true?
Most importantly I was also told that buying a new exhaust system for the bike would be a pain in the ass because 04/05 (Rubber mount, carb) bike require different exhaust because it's a rubber mount, but wouldn't that mean that all rubber mount sportsters from 04 forward would use the same system? I don't see why carb vs EFI would matter.
This is the bike.

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In 2007 EFI was introduced, so 2004-2006 stock exhaust would not have O2 sensors and be a direct swap.
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5th February 2023
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Flat Track Champion
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Join Date: Jan 2019
Location: UK
Posts: 636 Sportster/Buell Model: XL1200T Sportster/Buell Year: 2017
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To directly answer the question the EFI bikes have O2 sensors in the exhaust to monitor fuel burn and the system can tweak the mixture a bit up and down to compensate. Your bike not being EFI doesn't need the O2 sensors but the exhaust mount to a bracket affixed to the engine so it can all move as one lump.
Using SuperTrapp as an example they make 2-in-1 labelled for 2004 to 2013. They supply bungs to put in the O2 ports.
They also claim they will fit bikes with forwards and mid controls.
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