Question about Harley Davidson XLH 1000 Sportster Motorcycles
Points/condenser connect to the negative side. Ignition sw to the + side. Length of wires is not critical. Just measure how long you need or buy the stock wires from dealer. Any more questions, please reply.
Posted on Sep 13, 2010
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Posted on Jan 02, 2017
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Oct 11, 2014 | Motorcycles
MISFIRE AT IDLE OR UNDER LOAD
FIRST CHECK FOR STORED DTC's, deal with them and if necessary further:
DESCRIPTION AND OPERATION
Misfire conditions may be caused by a number of different things such as the battery condition, voltage and connections, fuel system problems and in odd situations also by RFI interferences. Often when diagnosing you can effectively find problem causes by substituting a know good part for one that you are not sure about. Things like a coil do not need to be completely removed/installed but you just need to connect it so it will work etc. There are inline HT Spark tester available that you can connect in series with HT wiring and if you do so and the test light flashes without interruption during the misfire event you can start by assuming that if the spark plug condition is good (that will be a guess as often a very good looking spark plug is in fact not so good) and the gap is correct, then the problem is not an ignition problem. This must be done on both cylinders of course unless you know that only one cylinder is misfiring. If the light flashes in a interrupted fashion you likely have an ignition problem and will need to test the HT wires, the spark plugs, the spark plug gap, external spark plug tips and connectors in the HT leads for rust, corrosion etc. and the coil primary and secondary windings etc.
FIRST start by turning the ignition off, remove the first spark plug wire and install an inline spark tester in series with the cable and the plug and then start the engine and observe the tester light which will, if all is operating correctly, flash once for each power stroke. Note the results and then do this for the second cylinder.
SECOND you can do a Power Ground Continuity test (usually done and best done, with a breakout box), NEVER connect or disconnect any wiring with the ignition switch in the ON position. Using a multimeter check for continuity between ECM and wiring harness terminal 10 (BK/GN wire) to ground and if there is continuity go to the next test but if there is NO continuity repair the poor ground on the (BK/GN) wire.
THIRD you can do a secondary spark test by connecting a spark tester between the first spark plug cable and ground, cranking the engine over for a few seconds, noting the results and then doing the same with the other cylinder. If spark jumper properly on both cylinders then check for faulty, worn or cracked spark plugs,
plug fouling due to mechanical problems or faulty/rusted/corroded connections at the plugs or at the coils and repair whatever problems are found.
FOURTH you can do a spark plug wire test by disconnecting the plug wires and measuring the resistance from one end to the other end of the wires. If the resistance is correct:
Spark Plug Cable Specifications:
SPECIFICATION FRONT REAR
Length in. (except FXS) 18.75-19.50 6.50-6.75
Length mm (except FXS) 476.3-495.3 165.1-171.5
Resistance-ohms (except FXS) 4688-13,007 1625- 4502
Length in. (FXS) 7.25-7.75 7.25-7.75
Length mm (FXS) 184.2-196.9 184.2-196.9
Resistance-ohms (FXS) 1813-5170 1813-5170
Go to the next test and if not replace the bad spark plug wire.
FIFTH you can do a carbon tracking inspection by inspecting the top of the ignition coils for carbon tracking and if there is any evidence of carbon replace the coil. If there is no apparent evidence of carbon tracking replace the coil with a known good unit and repeat the secondary spark test. And if spark now jumps as it should replace the coil. However, if spark still does not jump then perform the next test which is the Ignition Primary Wire Continuity Test.
Sixth you can perform an ignition coil primary wire continuity test by first turning OFF the Ignition Switch and then disconnecting the BCM and measuring the resistance between connector [242B] terminal L3 and connector [83B] terminal A while wiggling the connectors. If the resistance is constantly less than 0.5 Ohms go to the next test but if it is not then repair an intermittent problem on the (R/GN) wire.
Seventh you can do a battery to main fuse block voltage drop test with the engine running by measuring the voltage drop between the battery positive point and the main fuse connector [64B] terminal A. If the voltage drop is more than 1.0VDC repair the (R) wire between terminal A of connector [64B] and the connection point at the battery, including connections at the starter. If the voltage drop is not more than 1.0 VDC then check for corrosion or damage at the BCM connector .
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Inspect for the correct routing of the spark plug wires. Improper routing may cause cross-firing. Inspect each wire for any signs of cranks or splits in the wire. Inspect each plug wire boot for tearing, piercing, arcing, carbon tracking or a corroded terminal.
If there is any corrosion, carbon tracking or arcing indicated on a plug wire boot or terminal, both the plug wire and component it was connected to should be replaced.
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