Harley Davidson XL 1200 C Sportster Custom - Recent Questions, Troubleshooting & Support


Hi, Angela for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
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2006 Harley... | Answered on Jun 10, 2018


Hi, Cato no way Jose not even close, for more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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2006 Harley... | Answered on May 23, 2018


Hi, David and the usual suspects are:
1. Dirty or clogged or over oiled air filter.
2. Choke not seating properly.
3. Float level to high.
If you have changed your engine size, compression ratio, fuel delivery system, air filter size or flow rate, mufflers or exhaust system or a significant change in altitude your carburetors need re-tuning and if your fuel system (gas tank, filters, fuel valve, and carburetor) is contaminated with ethanol sludge, varnish, rust, dirt, water etc. or your bike has been sitting for months or years without running these components must be "PROPERLY" cleaned and reassembled "CORRECTLY" before any adjustments can be made. Tuning your carburetor is fairly simple once you understand the basic principals. You engine is a simple airbox sucking air in and blowing it out, it is finely tuned at the factory for maximum performance once you upset that delicate balance by changing air filters, camshafts or exhaust systems your performance may go down the and the engine may run poorly, you need to compensate the air-fuel mixture in the carburetor in order for the engine to run smoothly and at peak performance. If you are running multi carburetors you need to sync them first and make sure your air cleaner element is clean and dry for paper elements or lightly oiled for foam and meshed elements and properly installed. Here is how and where you compensate trouble: "TIP" if your engine "BOGS" you're not getting enough fuel.
1. Close to 1/8 throttle is managed by the air screw and pilot/slow jet.
2. 1/8 to 1/4 throttle is managed by the air-screw, pilot/slow jet, and throttle slide.
3. 1/4 to 1/2 throttle is managed by the throttle slide and jet needle.
4. 1/2 to 3/4 throttle is managed by the jet needle, needle jet, main jet, and air jet.
5. 3/4 to wide open throttle is managed by the main jet and air jet.
6. A wide open throttle is managed by the main jet.
If you are running lean, spark plug electrode color is white, engine runs hot and feels like it is starving for fuel you need to go up on the jet size or move the c-clip down one notch. If you are running rich, spark plug color is black or dark gray, the engine runs cool, and bogs down when accelerating you need to go down on jet size or move the c-clip up one notch. When your carburetor is properly tuned for maximum performance your spark plug electrode will be a light tan color like coffee with cream. If you prefer fuel economy over performance you can go down on main jet sizes until a satisfactory level of lower performance is acceptable versus MPH, your spark plug color will be whiter and your engine will run warmer. These tuning adjustments will only make improvements if your intake and exhaust system have no air leaks or sealing issues and the entire electrical system is in proper working order and you have no mechanical issues.
For more information about your issue and valuable "FREE" downloads that you will need for viewing and printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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2002 Harley... | Answered on May 09, 2018


Hi, Cyrel for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere $10 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on May 01, 2018


Hi, Jarrod for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Shifter Pawl Adjustment The Sportster and Buell Motorcycle Forum The...
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2002 Harley... | Answered on Apr 21, 2018


Hi, Keith before testing any electrical component in the Starting Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Engine Run Switch is "FAULTY" or corroded.
4. Check the battery terminals for damage or corrosion check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter.
5. Bank angle sensor needs a reset or is faulty.
6. FOB battery low or dead.
7. Faulty ignition switch.
8. Faulty starter button.
9. Faulty kickstand, clutch, neutral safety switch.
10. Security alarm needs a reset.
11. Starter relay, solenoid, starter motor or circuit wiring faulty.
12. Starter armature or field coils have failed.
13. Main fuse or circuit breaker may be blown or faulty.
14. Faulty ignition relay.
15. The electric starter is working but starter clutch has failed.
16. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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2004 Harley... | Answered on Mar 12, 2018


Hi, Anonymous you should have 2 short pushrods those are for the intake valves and 2 longer pushrods those are for the exhaust valves if one exhaust pushrod is longer than the other it goes in the front, for this scenario you will need your service manual, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on Feb 09, 2018


Hi, Lisa for this scenario you will need your service manual, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on Feb 08, 2018


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Harley Davidson... | Answered on Jan 30, 2018


Hi, Anonymous for more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day. How To Adjust Your Power Commander
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2006 Harley... | Answered on Jan 30, 2018


Hi, Thomas fuse and circuit breaker location are as follows:
SPORTSTER-Underneath the seat or behind the left side panel or inside the headlight bucket.
SOFTAIL-Underneath the seat behind the battery or under the speedometer housing.
DYNA-Behind the left side panel.
TOURING-Under speedometer housing or left and right side panel.
Under the speedometer housing or inside the headlight bucket location is for mechanical circuit breakers only.
The following is an approximate timeline of Circuit Breakers and Fuses.
1965-1990 circuit breakers only.
1990-2000 circuit breakers and fuses.
2000 and up fuses only.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Location fuse box 1993 1200 sportster Google Search
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Harley Davidson... | Answered on Jan 23, 2018


Hi, Cecil fuse and circuit breaker location are as follows:
SPORTSTER-Underneath the seat or behind the left side panel or inside the headlight bucket.
SOFTAIL-Underneath the seat behind the battery or under the speedometer housing.
DYNA-Behind the left side panel.
TOURING-Under speedometer housing or left and right side panel.
Under the speedometer housing or inside the headlight bucket location is for mechanical circuit breakers only.
The following is an approximate timeline of Circuit Breakers and Fuses.
1965-1990 circuit breakers only.
1990-2000 circuit breakers and fuses.
2000 and up fuses only.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
1993 Harley Sportster 1200 fuse box location Google Search
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Harley Davidson... | Answered on Dec 02, 2017


Hi, Ggggggggggggggg for this scenario you will need your service manual, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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2000 Harley... | Answered on Nov 26, 2017


Hi, Joseph before testing any electrical component in the Turn Signal Light Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test because your battery may have 12.5 volts or more but little or zero amps causing the battery to be faulty and must be replaced, "AGM" batteries fall into this category more so than lead-acid types, also before diagnosing any turn signal/running light/parking light issue make sure the bulb is good and the light fuse has continuity with a test light. If you have replaced your OEM lights with one or all LED lights you are going to need a load equalizer.
If no turn signals are working the cause could be a faulty turn signal module/flasher or the connector going to it, look for corroded, loose, or broken pins/sockets. Contact spray cleaner is great for removing corrosion.
If your turn signal comes on but takes several seconds before it starts flashing you may have dirty contacts in the turn signal switch/button, the switch needs to be opened up and cleaned also the flasher may be starting to fail. It should be noted that cold weather will only exacerbate the situation especially when temperatures drop down below freezing and the location of the component, turn signal switches on the handlebar are at the mercy of the oncoming freezing 70 mph wind and makes it hard for the contacts to do their job covered in frozen grease/grime
If all four turn signals flash at the same time like hazard lights even though you only pressed one turn signal button then you have a LED light in the circuit and need a load equalizer that can be purchased from any motorcycle parts supplier.
If your speedometer does not function properly it will have to be fixed first because your turn signal module gets the data from the speedometer for normal turn signal function.
If your front turn signals don't work use a test light to check for power and ground at the bulb socket, then start backtracking the wiring through every wire connector to the turn signal switch/button and check for continuity, go all the way back to the fuse if necessary to find the cause of the malfunction.
If your rear turn signals don't work check your rear fender wiring harness connector first for corroded, broken, loose pins/sockets, power, and a good ground, the harness connector is usually located under the seat on the front of the rear fender then keep tracing the wiring look for obvious harness damage caused by the rear tire.
If you still can't find the malfunction backtrack from the rear fender wiring harness connector.
If one side does not work you could have a faulty turn signal switch or module check for continuity.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
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2002 Harley... | Answered on Nov 20, 2017


Hi, Frank for this scenario you will need your service manual, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on Nov 05, 2017


Hi, Anonymous the positive battery cable goes to the starter from the starter post a black wire goes to the copper stud on a 50 amp circuit breaker from the silver post of the circuit breaker a red wire goes to the ignition switch, what you need is a wiring diagram that is in the back of your service manual if you can't find the first and best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information and questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on Nov 04, 2017


That is a common issue, the insulation breaks down when they heat up. Strange why they put the coil next to the cylinder head.
They last for about 5 - 7years as a rule, sometimes a lot longer.

Harley Davidson... | Answered on Nov 01, 2017


Hi, Chelsea "ABSOLUTELY" but get a new switch ASAP for this scenario you will need your service, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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2003 Harley... | Answered on Oct 23, 2017


Hi, Anonymous before testing any electrical component in the Charging System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. All voltage readings will be on the DC scale except for Stator Output which will be AC you will need a multi-meter to conduct the following tests. "WARNING" never plug or unplug any electrical connector in the charging system with the engine running !!!
1. Check battery terminals for damage or corrosion, check battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
2. Check the voltage drop at the battery when you hit the starter button, anything below 9.6 volts you might have a faulty battery.
3. Make sure your voltage regulator is properly grounded with a clean tight connection, then check voltage at the battery with the bike running between 2000-3600 RPM, depending on your system specs, your readings should be 14.3 to 14.7 volts. If you are not getting these numbers or the reading is 15 volts or higher replace the voltage regulator.
4. Faulty regulator diodes can allow excessive amounts of voltage going back to the battery causing it to overheat, boil its contents and swell the casing. The excessive voltage will also spike the charging system allowing light bulbs to surge brighter than normal until they fail along with the main circuit breaker.
5. Unplug the connector to the alternator and hook your multimeter leads to the alternator (pin/socket selection does not matter) set the multimeter to AC volts, at an idle the multimeter should read 16 to 20 volts AC. at 2,000 RPM 32 to 40 AC volts, 3,000 RPM 48 to 60 AC volts. If you are not getting these numbers, you may have a faulty alternator rotor.
6. Set the multimeter to OHM'S, connect one lead to the alternator (any pin/socket) and the other to a ground, the multimeter should read infinity. Connect both leads to the alternator multimeter should read 0.1 to 0.2 OHM'S. If you are not getting these numbers, you have a bad stator.
7. Check all wiring in the charging circuit for worn or chaffed spots and all wiring connectors in the circuit for corroded, broken, or loose pins/sockets, which is the # 1 offender.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Harley Sportster Charging System Testing tips
https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
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Harley Davidson... | Answered on Oct 21, 2017

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