Question about 2002 Harley Davidson XL 1200 C Sportster Custom

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The engines turns vigorously when I press the Start button, but won't run. There is plenty of fuel, the spark plugs were renewed about 3,500 miles ago [when it was serviced by a n HD dealer]. I have cycled the key from 'off' to 'ign' and back again - in accordance with the Owners Manual. On turning the key to 'ign', the following sequence occurs : Neutral light comes on and stays on until a gear is selected. Oil pressure light comes on and stays on until there's sufficient oil pressure, then it goes out. 'Red Key' light [immobiliser ?] comes on, then goes out after a second ot two. 'Engine' symbol comes on with Red Key, then goes out for a second or two, then comes on again. System Relay 'clicks' once, then clicks again after a second or two. On pressing the Start button, the engines turns normally, but does not start [engine symbol remains on]. All fuses have been checked for both corrosion and integrity - no problems found. Both System and Starter relays have been visually checked for corrosion on the connector pins - no problems. There is approx' 70 Ohms across the Starter solenoid terminals, and 'infinity' across the relay connecter terminals in it's default state. Unfortunately I have no separate 12v source to bench test the Starter Relay. Any clues ?? :-(

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If the starter turns the engine over, there's nothing wrong with the starter relay, the solenoid, or the starter. The reason your engine won't run is it has no spark for some reason. I'm afraid that this is all I can tell you. For some reason, the system is not firing the spark plugs. Check the fuse. I hope this helps but I must confess that I don't know a lot about Harley's new electronic system after 2000. I work on the older bike that don't have this system.

Good Luck
Steve

Posted on Sep 08, 2010

  • ian_hay Sep 10, 2010

    Thanks wd4ity. It turned out to be the System Relay; the second 'click' was the clue.

  • wd4ity
    wd4ity Sep 10, 2010

    A "system relay"? I've never heard of such a relay but then, like my profile says, I don't work on the bikes made after 1999. They've got all these computers (ECM) and stuff on them. I'm not afraid of that stuff or wiring having completely rewired many bikes in my life but I just don't know anything about the computer stuff. I guess I could learn but I've got plenty to keep me busy as the dealers won't work on anything built before 1986. Maybe I'll ride over to a friend of mine's house and ask where I can get the information and study up on it. Then I'll need to purchase the special tools I need to work inside the cam chest of a Twin Cam. Thanks Ian. Ride Safe now.
    Steve Bentley
    Forsyth, Ga.

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