Question about 2004 Harley Davidson XL 1200 C Sportster Custom
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Posted on Jan 02, 2017
SOURCE: starter not always turning motor
Possible solution. You probably know that harleys, unlike almost all the others used a bendix type to shove the starter motor's gears into engagement with the starter clutch. Since you replace the solenoid, the thing that pushes the gears into engagement; the battery, that would push the starter motor if the gears were in engaagement; and the starter motor, which would turn the ring gear if it was in engagement. So wht's left? Unfortunately it sound like it might be the teeth on either the ring gear or the bendix gear, probably the ring gear as it was notoriously weak on iron sportys. Not a problem you want to try to fix at home unless blessed with tools, room and time.
Posted on Apr 08, 2009
The advance timing should be 35° before Top Dead Center. This is how you find out which mark this is.
Get the rear wheel of the bike off the ground, remove the spark plugs, shift the bike into fourth gear, and remove the timing plug from the left engine case.
Now, take an ordinary PLASTIC DRINKING STRAW and insert it into the front spark plug hole. Do not use anything else or you stand a chance of it breaking and then you'll have to pull the head to get it out. The plastic straw will bend but not break.
Bump the rear wheel in the direction that it turns while riding down the road until the piston pushes the straw all the way up and just barely starts going back down. Look into the timing hole. You should see a timing mark. This is the Top Dead Center mark. Now, bump the rear wheel BACKWARDS until you see another mark. This should be the ADVANCED TIMING MARK. The piston should 7/16" down from top dead center.
On this model Sportster the timing is advanced by a mechanical advance mechanism. These units are notorious for wearing out and not contolling the timing very well. You must remove the breaker plate to inspect this mechanism. Mark the position of the plate before you remove it. If the pins and holes in the flyweights are worn, replace the unit. Replace it with a good needle bearing unit. Replace the points and reset the gap at 0.018 - 0.020".
Posted on Sep 24, 2009
Contact me directly and I'll try to scan you a copy of a wiring diagram for your 82 Ironhead. firstname.lastname@example.org The diagram I have is quite large and I'll have to send it to you in two .JPG format files. If that would be sufficient, let me know.
Posted on Dec 13, 2009
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