Harley Davidson XL 1200 C Sportster Custom - Recent Questions, Troubleshooting & Support


take it to the dealer, set up problem with EFi

2005 Harley... | Answered on Dec 06, 2019


Hi, Justin and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at the ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
6. Faulty ignition coil or electronic control module.
7. Faulty pulse coil.
8. Faulty CKP, CMP, or BAS sensor.
9. Faulty ignition switch.
10. Faulty run/off switch
11. Tilt sensor needs a reset.
12. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.hdforums.com/forum/sportster-models/1190269-help-no-spark-1988-sportster-1200-a.html
https://www.youtube.com/watch?v=B8kjjnupGTk
http://www.mediafire.com/file/nc0vlqn31bb4477/70-03_Harley_Sportster_Service_Manual.pdf/file
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/service/document/6300?highlight=1998+sportster+owner
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Harley Davidson... | Answered on Nov 12, 2019


Hi, Wayne and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, stator, magneto, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Faulty or corroded kill switch.
11. Accelerator pump damaged or not working.
12. Water or dirt in the fuel system, carburetor or filter.
13. Restricted, blocked or kinked fuel line.
14. Fuel tank empty.
15. The gas cap is not venting properly or fuel tank venting system blocked, loosen gas cap and go for a test ride.
16. A failed fuel pump, pressure regulator and or fuel injectors.
17. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
18. Needle and seat stuck closed in the float bowl.
19. Petcock clogged or damaged.
20. Lean angle switch is faulty or needs adjustment.
21. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.hdforums.com/forum/sportster-models/658451-1200-sportster-engine-dies-while-driving.html
Harley Davidson XLH Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm free owners manual
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2003 Harley... | Answered on Oct 21, 2019


Hi Karaandlarry, you have a lot going on at the same time I would try an alarm reset to start with, for more information about your question please visit the website below. Good luck and have nice day.
Set Change Override Transport Harley Security Alarm PIN Code No Key Fob...

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


2003 Harley... | Answered on Oct 19, 2019


Hi, Brandon sorry you can't find the first and best tool you ever bought for your Harley Davidson despair not for a mere $10 you can download another one. For more information about your issue and valuable free downloads that you will need please visit the websites below and for specific information or questions, please feel free to contact me at [email protected] Good luck and have a nice day. Torque specs diagrams or procedures manual
Harley Davidson Manuals Mark Workshop
http://www.stcharlesharleydavidson.com/OEMpartfinder.htm
Owner Manuals Harley Davidson USA

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

2003 Harley... | Answered on Oct 19, 2019


Hi, Alan and the usual suspects are:
1. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Spark plugs in bad condition or partially fouled.
4. Spark plug cables in bad condition and leaking.
5. Spark plug gap too close or too wide.
6. Faulty ignition coil, module, and or sensor.
7. Loose, dirty, or corroded ignition module connector at crankcase.
8. Faulty CKP or CMP, MAP, ETS, ATS, TPS, O2 sensor.
9. Intake air leak.
10. Water, dirt, or rust in the fuel system, carburetor and/or filter.
11. Fuel tank vent system plugged or carburetor vent line closed off.
12. Vacuum line from intake manifold to fuel valve is broken, cracked, pinched, or missing.
13. Carburetor controls misadjusted.
14. Damaged carburetor.
15. Incorrect valve timing.
16. Weak or broken valve springs.
17. Damaged intake or exhaust valve.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below, and for specific information or questions, please feel free to contact me at [email protected] Good luck and have nice a day.
Harley Davidson Manuals Mark Workshop
http://www.stcharlesharleydavidson.com/OEMpartfinder.htm
Owner Manuals Harley Davidson USA
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2003 Harley... | Answered on Oct 19, 2019


  • It should be set to .040 inches.
  • If they are not pre-installed, make sure that the crush washer and terminal nut are installed.

Harley Davidson... | Answered on Sep 30, 2019


Hi, Cari the correct spark plug for your Harley-Davidson model is HD 6R12 and gapped at .040". With a dab of Anti-Seize on the threads install using an applied torque of 15 ft-lbs.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.hdforums.com/forum/sportster-models/971233-spark-plug-gap.html
http://www.mediafire.com/file/nc0vlqn31bb4477/70-03_Harley_Sportster_Service_Manual.pdf/file
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/service/document/6300?highlight=1998+sportster+owner
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2000 Harley... | Answered on Aug 26, 2019


Hi, Ralph, the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts enquiry.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?sa=X&q=Center+to+center+distance+of+the+front+forks+2004+Harley+Davidson+XL1200C+Sportster+Custom&tbm=isch&source=univ&ved=2ahUKEwix_8zB07rjAhVvvlkKHfc1C4YQsAR6BAgAEAE&biw=1440&bih=757
2004 Harley Sportster Service manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA
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2004 Harley... | Answered on Jul 17, 2019


Hi, Susana fuse and circuit breaker location are as follows:
SPORTSTER
Fuses are underneath the seat or behind the left side panel. Circuit breakers are inside the headlight bucket.
SOFTAIL
Fuses are underneath the seat, directly behind the battery, underneath a black plastic cover that slides up.
Circuit breakers are under the speedometer housing cover in between the gas tanks.
FX
Main breaker on the positive battery post buss bar.
All other circuit breakers under the speedometer housing.
FXR
Circuit breakers are behind the left side panel
DYNA
Fuses are behind the left side panel.
Circuit breakers are behind the left side panel.
TOURING
Fuses are behind the left side panel.
Circuit breakers can be attached to the battery positive terminal or behind the instrument panel or under the speedometer housing panel or inside the headlight bucket.
The following is an approximate timeline of Fuses and circuit breakers.
1965-1990 circuit breakers only.
1990-2000 circuit breakers and fuses.
2000 and up fuses only.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.google.com/search?sa=X&q=Fuse+box+location+1999+Harley+Davidson+XL1200C+Sportster+Custom&tbm=isch&source=univ&ved=2ahUKEwjtl-32lrLjAhURWs0KHRDhCUAQsAR6BAgEEAE&biw=1440&bih=757
Harley Davidson XLH Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA
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2000 Harley... | Answered on Jul 13, 2019


Hi, Brainstorm I'm guessing 5/16" for more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day. http://sportsterpedia.com/doku.php/sportster_history:99xx-01
2004 Harley Sportster Service manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA Free owners manual.
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2004 Harley... | Answered on Jul 08, 2019


Hi, Lou for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.google.com/search?q=Wire+crimper+2000+Harley+Davidson+XL1200C+Sportster+Custom&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiw653EvKDjAhUJzlkKHec2ArYQ_AUIESgC&biw=1440&bih=757
http://www.mediafire.com/file/nc0vlqn31bb4477/70-03_Harley_Sportster_Service_Manual.pdf/file
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA Free owners manual.
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2000 Harley... | Answered on Jul 06, 2019


Hi, Dave for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.google.com/search?q=Wiring+diagram+2004+Harley+Davidson+1200+sportster+custom&tbm=isch&source=univ&sa=X&ved=2ahUKEwjczfXLlNriAhWN2FkKHdd9BZwQsAR6BAgAEAE&biw=1440&bih=757
http://www.mediafire.com/file/l6yf9cj68rct746/2004_Harley_Sportster_Service_manual.pdf/file
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA free owners manual
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2004 Harley... | Answered on Jun 08, 2019


Hi, Sans fuse and circuit breaker location are as follows:
SPORTSTER
Fuses are underneath the seat or behind the left side panel. Circuit breakers are inside the headlight bucket.
SOFTAIL
Fuses are underneath the seat, directly behind the battery, underneath a black plastic cover that slides up.
Circuit breakers are under the speedometer housing cover in between the gas tanks.
FXR
Circuit breakers are behind the left side panel
DYNA
Fuses are behind the left side panel.
Circuit breakers are behind the left side panel.
TOURING
Fuses are behind the left side panel.
Circuit breakers can be attached to the battery positive terminal or behind the instrument panel or under the speedometer housing panel or inside the headlight bucket.
The following is an approximate timeline of Fuses and circuit breakers.
1965-1990 circuit breakers only.
1990-2000 circuit breakers and fuses.
2000 and up fuses only.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
sportster fuses
http://www.mediafire.com/file/nc0vlqn31bb4477/70-03_Harley_Sportster_Service_Manual.pdf/file
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
Motorcycle Maintenance Services Harley Davidson USA
Instant Repair Help over the Phone To speak to me personally $6

Harley Davidson... | Answered on Jun 07, 2019


Hi, Troy before testing any electrical component in the Turn Signal Light Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test because your battery may have 12.5 volts or more but little or zero amps causing the battery to be faulty and must be replaced, "AGM" batteries fall into this category more so than lead-acid types, also before diagnosing any turn signal/running light/parking light issue make sure the bulb is good and the light fuse has continuity with a test light. If you have replaced your OEM lights with one or all LED lights you are going to need a load equalizer.
If no turn signals are working the cause could be a faulty turn signal module/flasher or the connector going to it, look for, corroded, loose, or broken pins/sockets. Contact spray cleaner is great for removing corrosion.
If your turn signal comes on but takes several seconds before it starts flashing you may have dirty contacts in the turn signal switch/button, the switch needs to be opened up and cleaned also the flasher may be starting to fail. It should be noted that cold weather will only exacerbate the situation especially when temperatures drop down below freezing and the location of the component, turn signal switches on the handlebar are at the mercy of the oncoming freezing 70 mph wind and makes it hard for the contacts to do their job covered in frozen grease/grime
If all four turn signals flash at the same time like hazard lights even though you only pressed one turn signal button then you have a LED light in the circuit and need a load equalizer that can be purchased from any motorcycle parts supplier.
If your speedometer does not function properly it will have to be fixed first because your turn signal module gets the data from the speedometer for normal turn signal function.
If your front turn signals don't work use a test light to check for power and ground at the bulb socket, then start backtracking the wiring through every wire connector to the turn signal switch/button and check for continuity, go all the way back to the fuse if necessary to find the cause of the malfunction.
If your rear turn signals don't work check your rear fender wiring harness connector first, for corroded, broken, loose pins/sockets, power, and a good ground, the harness connector is usually located under the seat on the front of the rear fender then keep tracing the wiring look for obvious harness damage caused by the rear tire.
If you still can't find the malfunction backtrack from the rear fender wiring harness connector.
If one side does not work you could have a faulty turn signal switch or module check for continuity.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
Sportster Turn signal problem fix Harley Davidson Forums
https://www.youtube.com/watch?v=D5d15eYnsl4
2006 Harley Sportster Service Manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
2006 Harley Davidson Sportster 1200 Custom Owner Manual
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2006 Harley... | Answered on May 14, 2019


Hi, Dianne for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
Changing speed sensor Harley Davidson Forums
https://www.youtube.com/watch?v=mncGf__XaI4
Harley Davidson XLH Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/mcpdf/Harley%20Davidson-1970-03%20Owners%20Manual.pdf
Instant Repair Help over the Phone To speak to me personally $6

Harley Davidson... | Answered on May 07, 2019


Hi, Jim for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
http://xlforum.net/forums/showthread.php?t=555972
https://www.youtube.com/watch?v=TkYKVQ8A4Yc
https://www.carlsalter.com/mcpdf/Harley-davidson-1970-78%20XL%20Service%20manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/mcpdf/Harley%20Davidson-1970-03%20Owners%20Manual.pdf

Harley Davidson... | Answered on Apr 25, 2019


Hi, Glen for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
https://www.youtube.com/watch?v=ut16TqBUYik
Harley Davidson XLH Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/mcpdf/Harley%20Davidson-1970-03%20Owners%20Manual.pdf
Instant Repair Help over the Phone To speak to me personally $6

2000 Harley... | Answered on Apr 22, 2019


Hi Anonymous, either your cables are adjusted too tight or they need to be lubricated, for more information on your question please visit the websites below and good luck:
How to Lubricate Throttle Cables on 2013 Harley Softail Deluxe
Harley Davidson Throttle Cable Adjustment

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



2006 Harley... | Answered on Dec 11, 2018


Hi, Mylo and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Faulty main circuit breaker and or connections.
4. Faulty ignition coil and or connections.
5. Faulty spark plug, oil or gas fouled, wrong heat range or service type, wrong gap, loose in the cylinder head, broken electrode or insulator.
6. Faulty spark plug cables, leaking or broken, internal damage check for spark leakage in the dark.
7. Faulty ignition module, switch, CKP, MAP, CMP, sensor and or any connector in the ignition circuit could have corroded, loose, or broken pins/sockets
8. Burnt exhaust valve or air leak in the exhaust system.
9. Improper valve clearance (too tight).
10. Check for generated diagnostic codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected] Good luck and have a wonderful day.
Sportster 1200 Custom Backfiring Harley Davidson Forums
2008 sportster 1200 backfire stumbles
2008 Harley Sportster Service Manual zip
Download WinZip
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
2008 Harley Davidson Sportster 1200 Custom Owner Manual
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2006 Harley... | Answered on Oct 07, 2018

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