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Anonymous Posted on Jul 21, 2008

04 1200 Sportster - backfires - cuts out - fouls plugs

Have had 2 dealer ships work on it - its been in the shop 3 of the last 4 weeks! Replaced crank sensor, replaced intake seal, rebuilt carburettor, and both shops have rejetted it. It starts after traveling less than 2 blocks and by the time I've traveled a mile its so bad it won't make another block without sitting for several hours!

  • Anonymous Aug 19, 2008

    03 sporty backfires fouls pulgs changed coil, wires, plugs

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  • Posted on Jul 30, 2008
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Turns out the crank sensor needed to be replaced again (second time in 8 weeks or so!). In the last week Harley has sent out a "improved" crank sensor that does not have the issues of the original. Therefore if you replace it once you shouldn't have to do it again and again. Bike runs great now. We will see - though - my local service manager promises it will stay that way.

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I bought a 92 fzr 600 ride it for a month no problem. But now it keeps popping the resistor in the spark plugs. 3 sets of plugs in the last 2 weeks. Last set lasted 2 days. All have been ngk.

NGK plugs dont stop, especially all at once, so there is another problem.
There are some resisters in the plug caps that can fail.
Are the plugs carbon fouling?(dry black) if so make sure the air filter is new, and oil is changed.
Does the enginge blow smoke or use oil?(wet black)oil fouled may mean rings.
Fuel fouled may mean the jettting is wrong or choke stuck open
Its the battery good(new) and charging ,put a multi meter across the terminals 12v stopped, 14v running approx.
it always helps to drain the carb bowls every few weeks
If exhaust is not standard, the jetting may be wrong.
does the fuel tap work correctly? only use the run or res positions never pri
A short in the kill switch or a worn ignition switch can cause a miss or backfire
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