Question about 2001 Harley Davidson XL Sportster 883 Hugger

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I have a 2003 XL 1200C. Will crank but wont start. If I hold down on start switch while turning the key ON it will fire one time then stop running. But, if I try to start again without turning the key back OFF first, then all it will do is crank. I have to keep turning the key OFF and ON to get it to fire one time. Is it the key switch, a relay, or the ignition module?

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  • Harley Davidson Master
  • 41,919 Answers

Hi Cj_wojtowicz, 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:
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 especially the negative cable at "BOTH" ends
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,
or cables connected to wrong cylinders.
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.
14. Security alarm system not disarming.
For a primary suspect please visit the website below. Good luck and have nice day.
Harley Davidson Sportster error codes and how to access them
Harley Davidson Wiring Diagrams and Schematics

Posted on Jun 26, 2015

  • Gregg Mahin
    Gregg Mahin Jun 26, 2015

    Hi Cj_wojtowicz, 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:

    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 especially the negative cable at "BOTH" ends

    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,

    or cables connected to wrong cylinders.

    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.

    14. Security alarm system not disarming.

    For a primary suspect please visit the website below. Good luck and have nice day.

    Set Change Override Transport Harley Security Alarm PIN Code No Key Fob...

    Harley Davidson Wiring Diagrams and Schematics

    Harley Davidson Sportster error codes and how to access them

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SOURCE: FIRE and FUEL........NOT CRANKING !!!!!!!

check your ignition fuses but i think your problem is between your module and ignition switch if you got safty switches on there any one of them can cause that also.

Posted on Dec 06, 2008

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SOURCE: 2003 dyna ignition breaking down

It never hurts to check your grounds, they have a habit of loosening up. It sounds like either the voltage regulator or the stator is failing to me. If you can get it to fail at home take a multi-meter and get a reading on the stator, I don't know the values on a dyna, but you should get a reading at idle and it should climb as you rev the motor. When my sporster did this it turned out to be the stator.

Posted on Jun 19, 2009

bozcro
  • 867 Answers

SOURCE: I have a 1999 1200c sportster. While riding down

well, if plugs are wet, try placing plugged in spark plug on the block, turn ingine, should spark blue. orange no good, none no. good lol.do both plugs and wires.if one works and the other one doesnt, you need a new plug.if both no good, having electronic ignition, most likely the coil is toast (make sure its plugged in good, cables and wires)

Posted on Jul 24, 2009

wd4ity
  • 4565 Answers

SOURCE: have a new ignition module and now the timing is

First off, you have to find the Front Cylinder Advanced timing mark on the flywheels. Lift the rear wheel of the bike off the ground and support it in a safe manner. Remove the spark plugs from the engine and put the transmission in fifth gear.

Now, using a common everyday plastic drinking straw (Note: don't use anything else or you may damage a piston or it may break off leaving part of whatever you used in the cylinder requiring the removal of the head) , bump the rear wheel in the direction of rotation until the front piston it at Top Dead Center. Remove the timing plug from the crankcase on the left side of the engine. You should see the TDC timing mark in the hole. If not, bump the engine slightly forward or backwards until you do. It should be a straight up and down line on the crank.

Now, slowly start bumping the rear wheel in the backwards direction. You may see a mark come into view that looks kinda like this "oo", this is a factory timing mark,not the front cylinder advanced mark. Continue bumping the rear wheel wheel in the backwards direction until you see the Front Cylinder Advanced mark. It will look like "dot" on the crankshaft "o". The piston should be approximately 7/16" down from TDC, If you go further, you will not see anymore marks until you come back around to the TDC mark.

NOTE, you may or may not have the front cylinder on the compression stroke. It doesn't matter, all you're doing right now is finding the correct timing mark. "

This is the mark you want to time the engine to. Put the transmission back in neutral. Reinstall the spark plugs and connect a timing light to the front cylinder spark plug. Start the engine and set the engine speed at 1300 -1500 RPM. Shine the light into the timing hole. You should see the Front Cylinder Advanced timing mark in the center of the hole. If not, you'll have to move the timing plate on the right side of the engine to get the timing mark in the center of the hole. Moving the plate clockwise advances the timing and moves the timing mark towards the rear of the timing hole. Moving the plate counterclocwise retards the timing and moves the timing mark towards the front of the timing hole.

Harley makes a clear plug to go into the timing hole that is supposed to prevent the oil spray from the oil when the engine is running. I've tried to use them but it is very difficult to see the timing mark when using one. There are other tools available, CleanTime or something like that, but I've never used them. I usually start the engine with the plug loosely screwed into the timing hole. Once I get the engine started and up to speed, I take the plug out. DO NOT GET YOUR FACE NEAR THE HOLE. The crankcase pressure will blow oil in your eye and it hurts. Stand back and a bit off to the side to view into the hole.

If you will contact me directly, I'll scan and send you a picture of what the timing marks look like. A picture is worth a thousand words. Contact me directly at wd4ity @ bellsouth.net

Good luck
Steve

Posted on Jun 12, 2010

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2009 harley davidson xl 1200c sportster wont start


Hi Anonymous, and the usual suspects are:
1.Ignition/Light Key Switch not in IGNITION position.
2.Engine Stop switch in the OFF position.
3.Discharged battery, loose or corroded connections check negative cable at "BOTH" ends. (solenoid chatters).
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For a prime suspect please visit website below. Good luck and have nice day.
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Step 1:

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