2002 Harley Davidson XL Sportster 883 - Answered Questions & Fixed issues

wires around the head stock for insulation damage and shorting out

2002 Harley... | Answered on Sep 18, 2016 | 100 views

Your clutch pack is coming apart from the inside. You have a pressure plate thatbis riveted together and the rivets are coming loose.... the outet primary needs to come off and the clutch pack needs to be pulled apart. I would order all new fibers and steels.

2002 Harley... | Answered on Feb 15, 2015 | 78 views

Could be shifter linkage adjustment otherwise transmission likely needs to come apart and be inspected.

2002 Harley... | Answered on Oct 18, 2014 | 254 views

WHAT about it???

2002 Harley... | Answered on Oct 18, 2014 | 26 views

Check your pick-up sensor located inside the timing cover, behind the adjustor plate. If the filament is not intact you will have no spark.
A defective coil, cam position sensor, or stator will also cause a no spark condition.
Ignition Coil Primary Circuit Test
Remove the coil. THEN set your ohmmeter scale to RX1 and place ohmmeter leads on the primary coil windings A (front of coil) to B (middle of coil), B to C (front of coil) and check for primary coil winding resistance which normal resistance range is 0.5-0.7 ohms. If primary resistance is not within this range check out test results below.

Ignition Coil Secondary Circuit Test
With the ignition coil removed from the motorcycle and the ohmmeter set to the RX1K scale place the ohmmeter leads on the secondary coil windings B (middle terminal) to
R (rear secondary terminal/socket), B to F (front secondary terminal/socket) and check for secondary coil winding resistance which normal resistance range will be 5.5-7.5K ohms. If secondary resistance is not within this range check out test results below.

Test Results
A low resistance value indicates a short in the coil winding which requires coil replacement.

A high resistance value might indicate that there is some corrosion/oxidation of the coil terminals requiring the coil terminals to be cleaned and the resistance test then repeated and if after the test is repeated the resistance is still high after the terminals were cleaned the coil must be replaced.
If there is an infinite ohms or no continuity) resistance value the coil is open and must be replaced.

2002 Harley... | Answered on Oct 14, 2014 | 209 views

This is not a Harley Sportster question so suggest you post it where it belongs so someone with expertise for your bike can see it and answer it. I do not have this expertise. Sorry and good luck.

2002 Harley... | Answered on Oct 14, 2014 | 64 views

The standpipe sits in the tank and connects the filter "sock". The only vents, or overflows, should either be from the carburetors (overflow) or vacuum vent (typically found on dirt bikes) on gas lid. You should have no lines that directly "vent" from the tank. It is possible you have the wrong tank installed on the bike. Just a suggestion. ^^ I hope this helps.

2002 Harley... | Answered on Apr 17, 2014 | 623 views

Check your chain tension, it could be flapping around when you shift from 1st gear to 2nd, as well as there could be some road grime inside the smaller sprocket housing.

2002 Harley... | Answered on Jan 23, 2014 | 119 views

Under the left side cover. above the oil tank though. It's kind of tucked in there.

I’m happy to assist further over the phone at https://www.6ya.com/expert/robert_5bac37c3cb991fdb

2002 Harley... | Answered on Nov 25, 2013 | 155 views

first thing check the float is set at the right hight, second, check there is no small bits of dirt on or around the needle valve take the float and needle valve out and blow it out with an air line both ways, third, replace the needle valve. good luck.

2002 Harley... | Answered on Nov 06, 2013 | 102 views

Pull spark plug boot off of spark plug.
Find a bolt that's a good, fairly tight fit into the metal contact of the spark plug boot.
Lay it on the head so the bolt is just barely off the metal surface and crank while watching.

You could remove spark plug and reinsert it into the boot, lay it on the head so the threaded/hex part is grounded to the metal, BUT some newer Harleys have a compression sensor, and if it senses no compression in a cylinder (like if the spark plug is removed), it won't spark.

2002 Harley... | Answered on Oct 13, 2013 | 92 views

When you open up your fuse box it will be the third fuse from the top.

2002 Harley... | Answered on Jan 18, 2013 | 117 views

Check the battery connections. If they're loose, this may be the problem.

2002 Harley... | Answered on Nov 06, 2012 | 156 views

Check that the bulb is good and is plugged into the connector all the way.

2002 Harley... | Answered on May 30, 2012 | 309 views

Sound like your switch maybe be bad or you have a wire wore thru and is making a ground, check your harness wires coming down thru your triple trees. Rick.

2002 Harley... | Answered on May 17, 2012 | 276 views

I'm not sure. This site does not sell parts but the last one I installed on a bike in my shop cost over $100. But, that was quite a while ago. Try http://www.bikebandit.com

Good Luck

2002 Harley... | Answered on Sep 14, 2011 | 98 views

The timing is adjusted by a valve shim kit that can be purchased anywhere Zongshen parts are supplied

2002 Harley... | Answered on Nov 28, 2013 | 778 views

The circut that supplies the current to the starter is through the battery cables. The smaller wires are simply control wiring. If you look at the rear fo your starter, you'll see a single small wire running to the back of the starter. This is the wire from your starter relay. It simply activates the solenoid. When the solenoid pulls it's plunger inward, it makes two large copper contacts inside the solenoid. The battery's positive cable is connected to one of the large contacts and the starter motor is connected to the other. The starter's ground is where it's bolted to the engine. The engine is bolted to the frame and the battery's negative cable connects to the frame. This is the high current path from the battery through the starter and back to the battery. Make sure all the connections are good, tight and clean. Did you purchase a battery with enough Cold Cranking Amps to start the engine? You can take the plate off the back of the starter, pull the plunger and spring out, and check the large copper contacts. If they look badly burned, you can replace them. But, the possibility exist that you may have a bad starter. The only way to tell that is to do a current draw test on it.

Good Luck

2002 Harley... | Answered on Jun 26, 2011 | 186 views

1 up, the rest down.

2002 Harley... | Answered on Jun 25, 2011 | 37 views

If there is spark at the plugs and gas reaching the cylinders then it will start. Please ensure both.

2002 Harley... | Answered on Jun 11, 2011 | 330 views

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