Question about 2003 Harley Davidson XLH Sportster 883 Hugger

2 Answers

Bike starts SOMETIMES. No spark SOMETIMES. Spark plugs are good. Coil is good. I have gas. Cam seems to be fine. Engine turns over but won't start. And finally engine will just cut off mid drive... We're pretty sure it's just losing it's spark. Carb is in great condition.

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  • bjmorett Jul 16, 2010

    I just need many solutions

  • bjmorett Jul 16, 2010

    Wasn't right. But good shot!

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2 Answers

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In that case you have a bad contact in the wiring. You should check for loose connectors , corroded wires and iffy switches. Since the problem is ignition related the first thing you should check is the key contact: remove the wires from the key switch, join them manually, tape them to prevent shorts and run the bike this way to see if the problem is gone. If it does you will know that the key is bad - replace it. You can also test the switch with an AVO meter but this is a job for 2 men - one to hold the contacts and the other to jiggle the key.

Posted on Jul 16, 2010

  • bjmorett Jul 16, 2010

    Are we referring to the ignition module? Or the actual physical key? Is it a possibility that the engine cut off switch is faulty?

  • Azrael SRL Jul 16, 2010

    Not the key itself, the key contact - when you turn it a switch is activated. See the wires that go to the key contact - when you turn the key they are connected. That connection (inside the key unit) is probably faulty.


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  • Master
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If the engine gets no spark sometimes, then I would suspect a coil, but you say the coil is good. Did you measure the resistance of the coil when hot vs. cold?

Good luck on this repair.

Posted on Jul 16, 2010

  • bjmorett Jul 16, 2010

    How would I go about doing that? The bike does seem to run better when it's cold.

  • Duane Wong
    Duane Wong Jul 16, 2010

    measure the primary and secondary coils of the coil with an ohm meter.

    I don't know the spec off hand.

    If it runs better cold than hot, something could be going wrong with it.



    But, it's a stab in the dark.



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Hi Anonymous, when checking for spark the CKP needs to measure the compression bump in order to send the correct signal to the ICM/ECM so always check for spark with either a third plug grounded or lift the end of the plug boot 1/2 " off one of spark plugs that are in the head. and the usual suspects are:
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11. Engine lubricant to heavy ( winter operation )
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13. Primary cam sproket spline sheared or missing spacer.
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For a primary suspect please visit the website below. Good luck and have nice day.
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

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Hi Anonymous, and the usual suspects are:
1. Fuel tank empty
2. Fuel supply valve turned off.
3. Fouled spark plugs.
4. Engine flooded with gasoline as a result of over use of enrichner.
5. Fuel valve or filter clogged.
6. Vacuum hose to automatic fuel supply valve disconnected, leaking, or pinched.
7. Discharged battery, loose or broken battery connections.
8. Loose wire connection at coil, battery or plug between ignition sensor and module.
9. Spark plug cables in bad condition and shorting, spark plug cable connections loose,
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10. Ignition timing incorrect due to faulty ignition coil, ignition module, or sensors " Manifold Absolute Pressure" "Camshaft Position Sensor" "Crank Position Sensor" "Brake Apply Sensor
11. Engine lubricant to heavy ( winter operation )
12. Sticking or damaged valves or push rod wrong length.
13. Primary cam sproket spline sheared or missing spacer.
For a primary suspect please visit the website below:
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Good luck

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

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I really have two issues; 1. Yesterday the bike started and ran fine, today it just turns and won't start. I replaced the spark plugs and ensured there was gas in it. 2. When I turn the key, or start...


Hi, Christopher and the usual suspects are:
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2. Fuel supply valve/petcock turned off.
3. Fouled spark plugs.
4. Engine flooded as a result of overuse of the enricher.
5. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
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Hi,

Initially, pls check/verify:
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  • temporarily remove the air cleaner/filter box/assembly and cover each crb opening with the palm of your hand while cranking. presence of gas would be noted with fuel on your palm;
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Incidentally, if no spark on plugs, check connectors to CDI, or starting with the clutch lever pulled.

Hope this be of initial help/idea. Pls post back how things turned up or should you need additional information. Good luck and kind regards. Thank you for using FixYa.

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