Question about 2002 Harley Davidson XL 1200 S Sportster Sport

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Sporty won't crank.

Hey to everyone, I got a head scratcher. My 07 XL1200 low won't start at all, it won't even give a good old fashioned try. When I trun the key on, I get all of the lights, indicators symbols, and flahing signals, and I can hear the fuel valve running open, and all looks and acts like it's going to do it's thing when I push that start button...But, when I do, nothing. Nada, zip, not even a burp. No cranking, no mis-start, Nothing. Just Dead, do nothing, silent button action. I checked all the fuses, and none are blown. I checked the battery voltage and found 11.70vdc avilable. Enough for cranking I would think. I checked for a code with the speedometer, and all codes say "none", Any Idea what can be done to get this putter back on the road ASAP????

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Take the leads off the battery and clean the mating surfaces with a wire brush and reinstall. Check all the grounds are tight. Put the battery on a charger on low overnight to get the voltage back to at least 12.5V and then try again. If you don't have a charger, they are under $20 at Walmart. If the starter still does not attempt to turnover, try jump to the battery positive terminal. If the starter turns over then, you know it is in the starter switching system. If not, starter?

Posted on Nov 20, 2008

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The breather bolts on my 2002 sporty won't come off ,dont want to snao them any suggestions?

Hi Anonymous, try hitting the head of the bolts a couple of times with a hammer, then just give the wrench a good smack with the hammer if it breaks the bolt you gave it your best shot. I have never broken one and i have run across some tuffy's in my past. Good luck

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Battery checks out good but scooter won't start or even try to crank. Been sitting for several months

I have this bike. This is what i would try. Charge battery, replace old fuel with fresh fuel, manual says 91 Octane. You can drain old fuel out from fuel filter line, also good to replace fuel filter and spark plug. Spark plug is accessed from small panel behind where your ankles would be while riding. Fuel filter is above kick starter. Try and kick start, note its not the power of the kick that matters, its the position of the kick mechinisim - doesn't always have to be from the very top, you have to feel it be at a point just befofre it engages then kick. and DON't give it throttle when you're starting. If 10 kicks fail. Wait for the fuel to dry out for a few minutes, easy to flood with repeat failed starts...

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I have a 2001 XL1200 Sporster and it just died one day while riding. If it cooled off, it would run for a little while and die again.

Have you checked to see if you have fuel IN THE CARBURETOR? In 1996, Harley went to a vacuum operated petcock and they've had troubles with them. The diaphragm in the backside of the petcock gets a hole in it and it doesn't allow for a full flow of fuel. Ride the bike with the air filter off until it quits. When it quits, look into the mouth of the carb with the engine not running and crank the throttle grip to wide open throttle. There is a brass nozzle standing just inside the mouth of the carb. When you crank the throttle grip to wide open, you should see a stream of gasoline squirt into the carb. If not, the carb has no fuel in it even though the fuel tank may be full. You'll have to drain the tank and remove the petcock. Take the plate off the backside and take a look at the diaphragm. Gently stretch it while holding it up to the light and check for holes. Personally, I'd replace the petcock with a high quality mechanical petcock and plug the vacuum hose. You'll have to manually turn the fuel on and off old-school style but you won't have anymore petcock problems.

Good Luck

Aug 03, 2011 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

I was on the freeway and my bike started making a loud tapping noise. I lost power, but was able to coast off the freeway. I got it started again and the engine noise was really loud. Took it into HD and...

The oil is "gooey". Hmm. Cold 20W50 oil is gooey. There is nothing else in the engine to change the consistancy of the oil. Now, your oil tank is accessible without any tools. Possiblility someone could have put something in your oil. A good sniff of the oil should tell the story on that. If it smells like sugar or syrup, that's a good clue.

Now, If the bike wre a big twin, I'd guess you lost a roller on a tappet. Big Twins are notorious for this but the header says your bike is Sporty. I've never seen a Sporty lose a roller tappet. The Sportster has a much better valve train geometry than a Big Twin.

Have you checked for a blown head gasket? Evo Sportsters are known to be more vulnerable to that than the big twins. The easy way to find that is wait until it gets dark, start the engine, and rev it up a few times. Watch for a sharp flame to pop out betweent he head and the cylinder. It's easily seen in the dark.

Other than that, anything I could tell you would be a guess at best. Take a long screwdriver and put on bone in your head just in front of your ear. With the engine running, touch the engine in various places and try to determine where the noise is coming from. Sometimes this isn't easy as the noise will have a tendency to "travel through the engine". Otherwise the only thing you can do is a compression test or a leakdown test.

Good Luck

Jun 29, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

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No fire at the plugs, battery fine, was running then just won't fire, checked for fire with spare plug on both cylinders, test light to coil wires no juice, 1993 Harley XL1200 sportster

Your Sporty has a fuse box somewhere. check the fuses to see if any are blown. Harley always puts their ignition systems on their own circuit. If you don't find anything that way, contact me directly at and I'll scan a trouble shooting chart in and send it to you. There's more to the late models than there was with the early models.

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Short to fuel injector on 07 xl1200 custom just in time for the season damnit. moving wires under the tank will give the pump power so i dont think its the pump but a connection. is this common? what...

Hi Glenrockdmat, your going to need a test light and a wiring diagram, to track continuity from the ECM to the fuel injectors for a free wiring diagram please visit the website below and good luck. Harley Davidson Wiring Diagrams and Schematics

Mar 31, 2010 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

Is there a larger gas tank I can put on my 2002 xl1200 sportster sport.

some of the aftermarket manufacturers make what they call a "king tank". I don't know how much more fuel that will give you if any at all. that's the biggest tank a Sporty that I've seen. Now, I have seen a set of Fat Boy tanks on a Sportster and they look good. Of course, this would require that you fabricate a custom mount for the tanks.

Jan 05, 2010 | 2002 Harley Davidson XL 1200 S Sportster...

2 Answers

Only idles with choke out

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