Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 8
fuel
hose and clamps . . . . . . . . . . . . 342
shutoff valve . . . . . . . . . . . 344-347
tank . . . . . . . . . . . . . . . . . . . . . . 344
intake manifold . . . . . . . . . . 340-342
1988-2003 models
carburetor. . . . . . . . . . . . . . . 350-366
specifications . . . . . . . . . . . . . . 390
fuel
hose and clamps . . . . . . . . 367-368
shutoff valve
1988-1994 models. . . . . . 373-375
1995-2003 models . . . . . . . . . 375
tank . . . . . . . . . . . . . . . . . . 370-373
intake manifold . . . . . . . . . . 366-367
starting enrichment valve
(choke) cable replacement . . . . 370
torque . . . . . . . . . . . . . . . . . . . . . 391
fuel tank capacity . . . . . . . . . . . . 26-27
line inspection . . . . . . . . . . . . . . . . 137
torque. . . . . . . . . . . . . . . . . . . . . . . 349
troubleshooting. . . . . . . . . . . . . . 60-88
type . . . . . . . . . . . . . . . . . . . . . . . . 113
Fuses, 1998-2003 models . . . . . . . . . 457
G
Gearcase,
cover and timing gears . . . . . . 214-221
General information
American tap and drill sizes . . . . . . . 29
conversion tables . . . . . . . . . . . . 27-28
decimal and metric equivalents . . . . 30
electrical system, fundamentals . 17-18
fasteners . . . . . . . . . . . . . . . . . . . . . 4-6
fuel tank capacity . . . . . . . . . . . . 26-27
general dimensions . . . . . . . . . . 24-26
gross vehicle weight rating (gvwr). . 26
manual organization . . . . . . . . . . . . . 1
metric tap and drill sizes . . . . . . . . . . 29
model designations . . . . . . . . . . . . . 24
overall motorcycle weight . . . . . . . . 26
safety . . . . . . . . . . . . . . . . . . . . . . . 2-3
serial numbers . . . . . . . . . . . . . . . . . . 3
service methods . . . . . . . . . . . . . 18-23
shop supplies . . . . . . . . . . . . . . . . . 6-8
storage . . . . . . . . . . . . . . . . . . . . 23-24
technical abbreviations . . . . . . . . 28-29
tools . . . . . . . . . . . . . . . . . . . . . . . 8-12
measuring tools . . . . . . . . . . . . 12-17
special tools . . . . . . . . . . . . 18, 30-31
torque. . . . . . . . . . . . . . . . . . . . . . . . 27
warnings, cautions and notes . . . . . . . 2
H
Horn . . . . . . . . . . . . . . . . . . . . . 450-452
I
Ignition module replacement . . . . . . . 58
Ignition system
1986-1997 models . . . . . . . . . 408-412
troubleshooting . . . . . . . . . . . . 44-51
1998-2003 models
except 1200S models . . . . . . 414-417
troubleshooting . . . . . . . . . . . 51-56
1998-2003 1200S models . . 412-414
troubleshooting . . . . . . . . . . . 56-60
idle speed adjustment . . . . . . . 146-147
ignition coil . . . . . . . . . . . . . . 417-418
switch . . . . . . . . . . . . . . . . . . . 447-448
timing
adjustment . . . . . . . . . . . . . . 144-147
specifications . . . . . . . . . . . . . . . 150
Intake manifold . . . . . . . . . . . . . 340-342
L
Laced wheels. . . . . . . . . . . . . . . 488-489
Leakdown test, troubleshooting . . 89-90
Lighting system. . . . . . . . . . . . . 426-437
switch . . . . . . . . . . . . . . . . . . . 447-448
Lubrication
control cables
(non-nylon lined) . . . . . . . . . . 122-123
clutch lever pivot pin . . . . . . . . . . . 123
drive chain . . . . . . . . . . . . . . . 123-124
engine
oil
and filter change . . . . . . . . 117-119
level check . . . . . . . . . . . . . . . . 115
specifications . . . . . . . . . . . . . . 149
primary drive/transmission
oil capacities . . . . . . . . . . . . . . . 149
fork oil
capacity . . . . . . . . . . . . . . . . . . . . 149
change . . . . . . . . . . . . . . . . . 121-122
front brake lever pivot pin . . . . . . . 123
periodic. . . . . . . . . . . . . . . . . . 114-124
recommended lubricants and
fluids . . . . . . . . . . . . . . . . . . . . . . 149
sidestand . . . . . . . . . . . . . . . . . . . . 124
throttle control grip . . . . . . . . . . . . 123
transmission
oil . . . . . . . . . . . . . . . . . . . . . 119-121
capacities . . . . . . . . . . . . . . . . . 149
speedometer cable
(1986-1994 models). . . . . . . . . . . 124
steering head . . . . . . . . . . . . . . . . . 124
M
Maintenance
fuel, type . . . . . . . . . . . . . . . . . . . . 113
periodic. . . . . . . . . . . . . . . . . . 124-138
routine safety checks . . . . . . . 113-114
schedule . . . . . . . . . . . . . 113, 147-148
specifications . . . . . . . . . . . . . . . . . 150
tire
inflation pressure, cold . . . . . . . . . 149
tires and wheels . . . . . . . . . . . . . . 114
torque. . . . . . . . . . . . . . . . . . . . . . . 150
Model designations . . . . . . . . . . . . . . 24
O
Oil
and filter changer . . . . . . . . . . 117-119
filter mount
1986-1990 models . . . . . . . . 231-232
1991-2003 models . . . . . . . . 232-233
level check . . . . . . . . . . . . . . . . . . . 115
pump. . . . . . . . . . . . . . . . . . . . 228-231
1986-1990 models . . . . . . . . 221-228
pressure switch . . . . . . . . . . . . . . . 449
specifications, . . . . . . . . . . . . . . . . 149
tank and lines . . . . . . . . . . . . . 190-192
inspection . . . . . . . . . . . . . . . . . . 115
transmission . . . . . . . . . . . . . . 119-121
P
Pistons and piston rings . . . . . . . 184-189
Primary drive
1986-1990 models . . . . . . . . . 254-261
cover . . . . . . . . . . . . . . . . . . 251-252
primary chain adjuster. . . . . . . . . 254
1991-2003. . . . . . . . . . . . . . . . 271-279
cover
1991-1993 models . . . . . . . 264-266
1994-2003 models . . . . . . . 267-269
primary chain
adjuster . . . . . . . . . . . . . . . . . . . 271
adjustment . . . . . . . . . . . . . 124-125
Periodic
S
Secondary drive
drive belt and sprockets. . . . . . 483-487
drive chain and sprockets . . . . 479-483
motorcycle stands . . . . . . . . . . . . . 466
Sidestand . . . . . . . . . . . . . . . . . . 598-599
lubrication . . . . . . . . . . . . . . . . . . . 124
Spark plugs . . . . . . . . . . . . . . . . 141-144
Spark test . . . . . . . . . . . . . . . . . . . 32-33
Speedometer/tachometer . . . . . . 437-440
cable lubrication
(1986-1994 models). . . . . . . . . . . 124
Specifications
brake . . . . . . . . . . . . . . . . . . . . . . . 589
carburetor
1986-1987 models. . . . . . . . . . . . 349
1988-2003 models. . . . . . . . . . . . 390
clutch
1986-1990 models. . . . . . . . . . . . 262
1991-2003 models. . . . . . . . . . . . 283
electrical . . . . . . . . . . . . . 112, 463-464
engine, top end. . . . . . . . . . . . . . . . 193
ignition, timing . . . . . . . . . . . . . . . 150
maintenance . . . . . . . . . . . . . . . . . . 150
oil. . . . . . . . . . . . . . . . . . . . . . . . . . 149
starter motor . . . . . . . . . . . . . . 112, 464
INDEX
603
18
Specifications (continued)
transmission, five-speed,
1991-2003 models . . . . . . . . 331-332
tune-up. . . . . . . . . . . . . . . . . . . . . . 150
wheels, front and rear . . . . . . . . . . . 496
Starting enrichement valve (choke)
cable adjustment
(1988-2003 models) . . . . . . . . . . . . 137
Starter . . . . . . . . . . . . . . . . . . . . 419-425
motor, specifications . . . . . . . . . . . 112
solenoid . . . . . . . . . . . . . . . . . 425-426
system, troubleshooting . . . . . . . 35-41
Steering
head lubrication . . . . . . . . . . . . . . . 124
steering head and stem . . . . . . 518-522
steering head bearing . . . . . . . 522-523
steering play adjustment . . . . . 523-524
Storage . . . . . . . . . . . . . . . . . . . . . 23-24
Suspension
front
and steering,
troubleshooting. . . . . . . . . . 104-111
front fork
1200S models . . . . . . . . . . 510-518
specifications . . . . . . . . . . . . . 524
except 1200S models. . . . . 503-510
oil capacity . . . . . . . . . . . . . . . . 524
handlebar . . . . . . . . . . . . . . . 500-503
torque . . . . . . . . . . . . . . . . . . 524-525
rear
rear swing arm . . . . . . . . . . . 528-532
shock absorbers . . . . . . . . . . 526-528
torque. . . . . . . . . . . . . . . . . . . . . . . 499
rear . . . . . . . . . . . . . . . . . . . . . . . 532
Switches . . . . . . . . . . . . . . . . . . 440-450
brakelight
front . . . . . . . . . . . . . . . . . . . 446-447
rear . . . . . . . . . . . . . . . . . . . . . . . 450
handlebar . . . . . . . . . . . . . . . . 441-446
ignition/lighting . . . . . . . . . . . 447-448
oil pressure. . . . . . . . . . . . . . . . . . . 449
testing . . . . . . . . . . . . . . . . . . . . . . 440
T
Throttle cables. . . . . . . . . . . . . . 135-136
Throttle control grip lubrication . . . . 123
Tire . . . . . . . . . . . . . . . . . . . . . . 490-495
and wheels . . . . . . . . . . . . . . . . . . . 114
inflation pressure . . . . . . . . . . . . . . 496
cold . . . . . . . . . . . . . . . . . . . . . . . 149
Tools . . . . . . . . . . . . . . . . . . . . . . . . 8-12
engine
lower end. . . . . . . . . . . . . . . . . . . 197
top end . . . . . . . . . . . . . . . . . . . . 151
measuring tools . . . . . . . . . . . . . 12-17
special tools . . . . . . . . . . . . . 18, 30-31
Torque
body . . . . . . . . . . . . . . . . . . . . . . . . 600
brake . . . . . . . . . . . . . . . . . . . . . . . 589
clutch
1986-1990 models. . . . . . . . . . . . 263
1991-2003 models. . . . . . . . . . . . 283
electrical . . . . . . . . . . . . . . . . . . . . 465
emission control. . . . . . . . . . . . . . . 349
engine
lower end . . . . . . . . . . . . . . . 249-250
top end . . . . . . . . . . . . . . . . . . . . 196
exhaust system
1986-1987 models. . . . . . . . . . . . 349
1988-2003 models. . . . . . . . . . . . 391
fuel
1986-1987 models. . . . . . . . . . . . 349
1988-2003 models. . . . . . . . . . . . 391
general . . . . . . . . . . . . . . . . . . . . . . . 27
maintenance . . . . . . . . . . . . . . . . . . 150
suspension
front . . . . . . . . . . . . . . . . . . . 524-525
rear . . . . . . . . . . . . . . . . . . . . . . . 532
transmission
five-speed, 1991-2003 models . . 332
four-speed, 1986-1990 models . . 303
tune-up. . . . . . . . . . . . . . . . . . . . . . 150
wheels . . . . . . . . . . . . . . . . . . . . . . 499
Transmission
five-speed,
1991-2003 models . . . . . . . . 304-308
access door bearings . . . . . . 328-329
main drive gear . . . . . . . . . . 323-328
mainshaft and countershaft . 312-323
right transmission case
bearings . . . . . . . . . . . . . . . 329-330
shift forks and shift drum . . . 308-312
shift mechanism . . . . . . . . . . . . . 330
specifications . . . . . . . . . . . . 331-332
torque . . . . . . . . . . . . . . . . . . . . . 332
four-speed, 1986-1990 models 284-296
countershaft end play thrust
washer selection . . . . . . . . . . . . 303
countershaft gear spacer
selection chart . . . . . . . . . . . . . . 302
countershaft washers . . . . . . . . . . 302
early and late style gear
outside diameters . . . . . . . . . . . 301
gear ratios . . . . . . . . . . . . . . 301-302
mainshaft end play thrust
washer selection . . . . . . . . . . . . 303
service . . . . . . . . . . . . . . . . . . . . . 301
shifter mechanism . . . . . . . . 296-300
torque . . . . . . . . . . . . . . . . . . . . . 303
oil . . . . . . . . . . . . . . . . . . . . . . 119-121
neutral indicator switch . . . . . 449-450
troubleshooting. . . . . . . . . . . . . . 90-91
Troubleshooting
brake . . . . . . . . . . . . . . . . . . . . . . . 111
charging system . . . . . . . . . . . . . 41-44
clutch . . . . . . . . . . . . . . . . . . . . . . . . 90
electrical
component replacement . . . . . . . . 35
specifications. . . . . . . . . . . . . . . . 112
testing . . . . . . . . . . . . . . . . . . . 91-95
electronic speedometer/
tachometer . . . . . . . . . . . . . . . 95-101
engine
lubrication . . . . . . . . . . . . . . . . . . . 90
noises . . . . . . . . . . . . . . . . . . . . . . 88
performance . . . . . . . . . . . . . . . 34-35
smoke . . . . . . . . . . . . . . . . . . . . . . 89
starting . . . . . . . . . . . . . . . . . . . 32-34
excessive vibration . . . . . . . . . . . . 104
fuel system . . . . . . . . . . . . . . . . . 60-88
ignition system
1986-1997 models . . . . . . . . . . 44-51
1998-2003 models, except
1200S models . . . . . . . . . . . . 51-56
1998-2003 1200S models . . . . 56-60
leakdown test . . . . . . . . . . . . . . . 89-90
starting system . . . . . . . . . . . . . . 35-41
suspension, front and
steering . . . . . . . . . . . . . . . . . 104-111
Troubleshooting, transmission . . . 90-91
turn signal module
1997-2003 models. . . . . . . . . . . . 104
1991-1996 models . . . . . . . . 101-104
starter motor, specifications . . . . . . 112
Tune-up . . . . . . . . . . . . . . . . . . . . . . 139
air filter. . . . . . . . . . . . . . . . . . 139-140
compression test . . . . . . . . . . . 140-141
ignition timing
adjustment . . . . . . . . . . . . . . 144-147
specifications . . . . . . . . . . . . . . . 150
spark plug . . . . . . . . . . . . . . . . 141-144
specifications . . . . . . . . . . . . . . . . . 150
torque. . . . . . . . . . . . . . . . . . . . . . . 150
Turn signal
module
1991-2003 models . . . . . . . . 454-456
1991-1996 models,
troubleshooting . . . . . . . . 101-104
1997-2003 models,
troubleshooting . . . . . . . . . . . . . 104
flasher, 1986-1990 models . . . 453-454
V
Valve
tappet, 1991-2003 models . . . 213-214
tappets and guides,
1986-1990 models . . . . . . . . 210-212
valves and valve
components. . . . . . . . . . . . . . 169-175
W
Wheels
balance. . . . . . . . . . . . . . . . . . . . . . 490
disc and cast wheels . . . . . . . . 489-490
front wheel . . . . . . . . . . . . . . 466-469
bearing spacer shims,
late 1991-1999 models . . . . . . . 496
bearing spacer sleeves
1986-early 1991 models . . . . . . 496
hub
front
1986-1999 models . . . . . . . 469-473
2000-2003 models . . . . . . . 473-474
rear
1986-1999 models . . . . . . . 476-479
2000-2003 models . . . . . . . . . . 479
604
INDEX
Wheel (continued)
laced . . . . . . . . . . . . . . . . . . . . 488-489
truing . . . . . . . . . . . . . . . . . . 488-489
rear wheel . . . . . . . . . . . . . . . . 474-476
bearing spacer shims,
late 1991-1999 models . . . . . . . 497
bearing spacer sleeves
cast wheel,
1986-early 1991 models . . . . . 496
laced wheel,
1986-early 1991 modles . . . . . 497
rim and laced wheel service. . . 488-489
runout. . . . . . . . . . . . . . . . . . . . . . . 487
specifications, front and rear . . . . . 496
torque. . . . . . . . . . . . . . . . . . . . . . . 499
tubeless tire, specifications
1986 models . . . . . . . . . . . . . . . . 497
1987-1990 models. . . . . . . . . . . . 497
1991-2003 models . . . . . . . . 497-498
tube-type tire, specifications
1986-1990 models. . . . . . . . . . . . 498
1991-2003 models. . . . . . . . . . . . 498
torque. . . . . . . . . . . . . . . . . . . . . . . 499
truing . . . . . . . . . . . . . . . . . . . 488-489
Wiring diagrams . . . . . . . . . . . . 606-629
INDEX
605
18
can only be stopped by removing the jumper
wire. Test by removing the jumper wire before
riding the motorcycle. It is suggested to test
ride the motorcycle on a paved surface in a
secluded area away from all traffic. If you do
not feel that you can perform this test safely,
or if you do not have access to a safe riding
area, refer testing to a dealership.
6. Test-ride the motorcycle. If the problem has stopped,
use voltage drop and wiggle tests to identify an intermittent
open caused by a broken wire, poor connection, or defec-
tive switch in the starter safety circuit. If the problem con-
tinues, look for an intermittent open in the ignition control
module and cam position sensor wiring.
7. Stop the motorcycle and then shift it into neutral. Dis-
connect the jumper wire and reconnect the white wire
(1986-1993 models) at the ignition coil terminal.
Ignition Coil Testing
Disconnect the coil secondary and primary wires before
testing. Refer to Figure 40. Compaire readings to specifica-
tions noted in Table 2.
NOTE
When switching between ohmmeter scales in
the following tests, always cross the test leads
and zero the needle to assure a correct read-
ing (analog meter only).
1. Measure the coil primary resistance between both coil
primary terminals.
2. Measure the coil secondary resistance between both sec-
ondary terminals.
3. Replace the ignition coil if either test is not within speci-
fication.
Ignition Control Module and Sensor
Resistance Testing (1986-1990 Models)
The following tests require a Fluke 23 or Harley-
Davidson KMT multimeter (part No. HD35500). If any
other meter is used, the results may be different than the
specified values listed in these tests.
TROUBLESHOOTING
49
2
39
To ignition module
Ignition coil
16 Ga. jumper wire
Disconnect
Ignition
stop
switch
Ignition
switch
Main
circuit
breaker
Battery
40
Secondary terminals
Ohmmeter
Primary terminals
1. 1986-1993 models: white
1994-1997 models: white/black
2. 1986-1990 models: blue
1991-1997 models: pink
Ignition module ground test
1. Remove the outer timing cover, inner timing cover and
gasket as described in Chapter Twelve
2. Disconnect the sensor (Figure 38).
3. Connect the ohmmeter positive lead to the module con-
nector black pin and the ohmmeter negative lead to ground.
4. The correct resistance reading should be 0-1 ohms. If the
reading exceeds 1 ohm, replace the module.
5. Reconnect the connector.
Power supply diode test
1. Disconnect the white ignition coil-to-module connector
(Figure 39).
2. Connect the ohmmeter positive lead to the white igni-
tion coil connector and the negative lead to the module
ground wire. The resistance should be 800-1300 ohms.
3. Switch the test leads. The ohmmeter reading should be
infinite.
4. Replace the module if any test readings are incorrect.
5. Reconnect the ignition coil-to-module connector.
Coil driver transistor check
1. Disconnect the blue ignition coil-to-module connector
(Figure 39).
2. Connect the ohmmeter positive lead to the blue ignition
coil connector and the negative lead to the module ground
wire. The ohmmeter reading should be infinite.
3. Switch the test leads. The resistance should be 400-800
ohms.
4. Replace the module if any readings is incorrect.
5. Reconnect the ignition coil-to-module connector.
Ignition sensor ground test
1. Remove the outer timing cover, inner timing cover and
gasket as described in Chapter Twelve.
2. Disconnect the sensor (Figure 38).
3. Connect the ohmmeter positive lead to the sensor con-
nector red pin and the ohmmeter negative lead onto the sen-
sor plate.
4. The ohmmeter should read infinite resistance.
5. Check the sensor connector black and green pins. In
each case, the ohmmeter should read infinite resistance.
6. If any reading other than infinite was recorded, replace
the sensor plate.
7. Reconnect the sensor connector.
Ignition sensor output test
1. Remove the outer timing cover, inner timing cover and
gasket as described in Chapter Twelve.
2. Disconnect the sensor connector (Figure 38).
3. Connect the ohmmeter positive lead to the sensor con-
nector green pin and the ohmmeter negative lead to the sen-
sor connector black pin. The correct resistance reading
should be infinite.
4. Switch the test leads. The resistance reading should be
300-750 ohms.
5. Replace the sensor plate if any test readings are incor-
rect.
6. Reconnect the module to sensor connector.
Ignition Module and Sensor Resistance Testing
(1991-1997 Models)
The following tests require a Fluke 23 or Harley-
Davidson KMT multimeter (part no. HD35500). If any
other meter is used, the results may be different than the
specified values listed in these tests.
Refer to Figure 41.
1. Disconnect the battery negative terminal. (Chapter
Twelve).
2. Remove the outer timing cover, inner timing cover and
gasket as described in Chapter Twelve
3. Disconnect the sensor (Figure 38).
4. Connect the positive ohmmeter lead to the black module
pin and the negative ohmmeter lead to ground.
5. The correct resistance reading is 0-1 ohm. If the reading
exceeds 1 ohm, replace the module.
6. Reconnect the connector.
50
CHAPTER TWO
41
Control
module
side*
Ohmmeter
Chassis
ground
1. 1991-1994 models: red
1995-1997 models: red/white
2. 1991-1994 models: green
1995-1997 models: green/white
3. 1991-1994 models: black
1995-1997 models: black/white
*NOTE: This connector is triangular on
1995-1997 models.
Ignition Module Harness Resistance Test
(1991-1997 Models)
Refer to Figure 43
1. Turn the ignition stop switch (Figure 42) to the off posi-
tion.
2. Disconnect the 7-prong ignition module electrical con-
nector.
3. Disconnect the sensor plate 3-prong electrical connector.
4. On 1991-1993 models connect the positive ohmmeter
lead to the No. 4 ignition module connector on the wiring
harness side, not on the module side. On 1994-1997 models
connect the positive ohmmeter lead to pin No. 7 on the igni-
tion module connector on the wiring harness side, not on
the module side. Connect the negative ohmmeter lead to a
good engine ground. Wiggle the wiring harness and read
the resistance indicated on the ohmmeter. It should be 0-1
ohm. Note the following:
a. If the resistance reading is correct, perform Step 5.
b. If a high resistance reading is obtained, check for
dirty or loose-fitting terminals or a bare or damaged
wire; clean and repair as required.
5. Connect the positive ohmmeter lead to the No. 1 ignition
module connector socket on the wiring harness side, not on
the module side. Connect the negative ohmmeter lead to a
good ground. Wiggle the wiring harness and read the ohm-
meter scale. It should be infinity (high resistance). Note the
following:
a. If the reading is infinity, perform Step 6.
b. If the meter shows a resistance reading, the wire is
shorting to ground. Repair the wire and retest.
c. On 1991-1993 models, repeat this test for the follow-
ing ignition module connector sockets: No. 2, 3, 5, 6
and 7.
d. On 1994-1997 models, repeat this test for the follow-
ing ignition module connector sockets: No. 2, 3, 4, 5
and 6.
6. Check each of the ignition module socket wires (except
No. 4 on 1991-1993 models or No. 7 on 1994-1997 models)
for continuity with an ohmmeter set on the appropriate
scale. The reading for each wire should be 0-1 ohm. An in-
finite reading indicates that there is an open in the wire;
check for a dirty, loose-fitting or a damaged connector or
wire. Repair as needed and retest.
IGNITION SYSTEM
(ALL 1998-2003 MODELS
[EXCEPT 1200S MODELS])
Review
Precautions
and
Troubleshooting Preparation
in
Ignition System (1986-1997 Models)
in this chapter.
Refer to the wiring diagrams at the end of this manual.
Tools
Troubleshooting the ignition system requires a breakout
box (part No. HD-42682) as well as the breakout box har-
ness adapters (part No. HD-42962). When connected inline
in the ignition system, the breakout box provides test points
for checking a live circuit.
If the breakout box is not available, fabricate a test har-
ness (Figure 44) from 12 lengths of 16-gauge wire, a male
Deutsch (6-pin) connector and two female Deutsch connec-
tors (6-socket). Wire the No. 1 pin on the male connector to
the No. 1 socket on each female connector. No. 2 pin to No.
2 socket, etc.
During testing, connect the harness between the two ends
of the ignition control module connector (Figure 45) when
instructed to install the test harness. Probe the second fe-
male connector at the indicated test points.
Troubleshooting the ignition system also requires the
Harley-Davidson harness test kit (part No. HD-41404).
Different-sized terminals are used in the connectors on a
Sportster. This kit is equipped with different-sized probes
for checking the voltage and resistance of the various-sized
terminals without damaging the wire insulation.
Troubleshooting Tests
1. Perform the procedures described in
Troubleshooting
Preparation
in this chapter.
2. Perform the spark test described in
Starting the engine
in
this chapter.
a. If there is good spark, the problem is not in the igni-
tion system. Check the fuel system.
b. If there is no spark or only a weak one, recheck with a
new spark plug(s). If the condition remains the same
with new spark plugs and if all external wiring connec-
tions are good, the problem is most likely in the igni-
tion system; perform the
Ignition Test (Continuous or
No Spark at Spark Plug)
described in this section.
Ignition Test
(Continuous or No Spark at Spark Plug)
1. To perform this test, the battery must be fully charged.
Check the battery as described in Chapter Twelve.
2. Make sure the ignition module ground is good.
NOTE
When performing the following test proce-
dures, it will be necessary to fabricate a test
TROUBLESHOOTING
51
2
42
52
CHAPTER TWO
43
Unplug
Ohmmeter
Chassis
ground
Unplug 3-prong
sensor plug
Connect the positive ohmmeter
lead to pin No. 7 when testing
1994-1997 models. See text.
Sensor plate
Ignition
module
connector
Ignition coil
Ignition module
sensor
Vacuum
switch
1. 1991-1997 models: pink
2. 1991-1997 models: white
3. 1991-1997 models: black
4. 1991-1997 models: violet/white
5. 1991-1993 models: green
1994-1997 models: green/white
6. 1991-1993 models: black
1994-1997 models: black/white
7. 1991-1993 models: red
1994-1997 models: red/white
3-prong
connector
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