20 Most Recent 2002 Harley Davidson XL 1200 C Sportster Custom Questions & Answers


Hi, David and the usual suspects are:
1. Dirty or clogged or over oiled air filter.
2. Choke not seating properly.
3. Float level to high.
If you have changed your engine size, compression ratio, fuel delivery system, air filter size or flow rate, mufflers or exhaust system or a significant change in altitude your carburetors need re-tuning and if your fuel system (gas tank, filters, fuel valve, and carburetor) is contaminated with ethanol sludge, varnish, rust, dirt, water etc. or your bike has been sitting for months or years without running these components must be "PROPERLY" cleaned and reassembled "CORRECTLY" before any adjustments can be made. Tuning your carburetor is fairly simple once you understand the basic principals. You engine is a simple airbox sucking air in and blowing it out, it is finely tuned at the factory for maximum performance once you upset that delicate balance by changing air filters, camshafts or exhaust systems your performance may go down the and the engine may run poorly, you need to compensate the air-fuel mixture in the carburetor in order for the engine to run smoothly and at peak performance. If you are running multi carburetors you need to sync them first and make sure your air cleaner element is clean and dry for paper elements or lightly oiled for foam and meshed elements and properly installed. Here is how and where you compensate trouble: "TIP" if your engine "BOGS" you're not getting enough fuel.
1. Close to 1/8 throttle is managed by the air screw and pilot/slow jet.
2. 1/8 to 1/4 throttle is managed by the air-screw, pilot/slow jet, and throttle slide.
3. 1/4 to 1/2 throttle is managed by the throttle slide and jet needle.
4. 1/2 to 3/4 throttle is managed by the jet needle, needle jet, main jet, and air jet.
5. 3/4 to wide open throttle is managed by the main jet and air jet.
6. A wide open throttle is managed by the main jet.
If you are running lean, spark plug electrode color is white, engine runs hot and feels like it is starving for fuel you need to go up on the jet size or move the c-clip down one notch. If you are running rich, spark plug color is black or dark gray, the engine runs cool, and bogs down when accelerating you need to go down on jet size or move the c-clip up one notch. When your carburetor is properly tuned for maximum performance your spark plug electrode will be a light tan color like coffee with cream. If you prefer fuel economy over performance you can go down on main jet sizes until a satisfactory level of lower performance is acceptable versus MPH, your spark plug color will be whiter and your engine will run warmer. These tuning adjustments will only make improvements if your intake and exhaust system have no air leaks or sealing issues and the entire electrical system is in proper working order and you have no mechanical issues.
For more information about your issue and valuable "FREE" downloads that you will need for viewing and 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 xlch@mail.com. Good luck and have a wonderful day.
2000 sportster running rich Harley Davidson Forums
https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/pdfs/Harley%20Davidson-1970-03%20Owners%20Manual.pdf
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2002 Harley... | Answered on May 09, 2018


Hi, Jarrod 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 xlch@mail.com. Good luck and have a wonderful day.
Shifter Pawl Adjustment The Sportster and Buell Motorcycle Forum The...
https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/pdfs/Harley%20Davidson-1970-03%20Owners%20Manual.pdf
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2002 Harley... | Answered on Apr 21, 2018


Hi, Joseph 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. Good luck and have a wonderful day.
Sportster Turn signal problem fix Harley Davidson Forums
https://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://www.harley-davidson.com/content/h-d/en_US/home/owners/maintain-your-bike/owners-manual.html Instant Tech Relief To speak to me personally absolutely "FREE"

2002 Harley... | Answered on Nov 20, 2017


Hi, Anonymous for this scenario you will need your service, 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 and 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 xlch@mail.com. Good luck and have a wonderful day.
CHROME 1 5 034 ROCKER BOX OIL PRESSURE GAUGE KIT 0 60PSI HARLEY SPORTSTER...
Harley Davidson XLH Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://www.harley-davidson.com/content/h-d/en_US/home/owners/maintain-your-bike/owners-manual.html
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2002 Harley... | Answered on Jul 24, 2017


Hi, Robert and the usual suspects are:
1. Idle circuit and transfer ports clogged.
2. Air fuel mixture adjustment too lean.
3. Pilot jet clogged.
4. Faulty accelerator pump.
5. Float level too low.
6. Float bowl contaminated old fuel, water, dirt, rust, etc.
7. Float bowl vent or overflow tube clogged.
8. Fuel flow to carburetor restricted.
9. Intake manifold leak.
10. The gas cap is not venting properly or fuel tank venting system blocked.
11. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
12. Needle and seat stuck closed in the float bowl.
13. Multi carburetors not in sync.
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 xlch@mail.com. Good luck and have a wonderful day.
Engine cutting out
http://www.carlsalter.com/pdfs/Harley%20Davidson%20%20Sportster%201986-2003%20Service%20Manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://www.harley-davidson.com/content/h-d/en_US/home/owners/maintain-your-bike/owners-manual.html
Instant Tech Relief To speak with me personally absolutely "FREE"

2002 Harley... | Answered on Feb 14, 2017


Hi, Jason read the first link completely for this scenario you will need a service/owners manual if you can not find the first and best tool you ever bought for your Harley, despair not, for a mere $5 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a nice day.
Gauge cluster problem
Harley Davidson Manuals Mark Workshop
http://www.stcharlesharleydavidson.com/OEMpartfinder.htm
https://serviceinfo.harley-davidson.com/sip/index
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2002 Harley... | Answered on Aug 02, 2016


Hi, Anonymous sorry you can not find the first and best tool you ever bought for your Harley 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 click on the links below, and for specific information or questions feel free to contact me at xlch@mail.com. Good luck and have a nice day.
Delboy Garage Harley Sportster Rear Brake service
Harley Davidson Manuals Mark Workshop
http://www.stcharlesharleydavidson.com/OEMpartfinder.htm
Owner Manuals Harley Davidson USA
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2002 Harley... | Answered on Apr 28, 2016


Hi Scott, and the usual suspects are:
1. No fuel in gas tank.
2. Fuel valve not switched to on or reserve.
3. Fuel cap not venting properly.
4. Fuel filter clogged.
5. Vacuum line broken, cracked or not connected to petcock or intake manifold.
6. Fuel valve diaphram faulty.
7. Fuel line to carburator blocked or kinked.
8. Float valve needle stuck to seat.
Good luck.

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

2002 Harley... | Answered on Jun 07, 2015


Hi Kmccarty, 4 out of 5 Harley Gods give this one a thumbs up, but just to be on the safe side contact your local dealers parts department for confirmation. Good luck

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

2002 Harley... | Answered on Jun 02, 2015


Hi Scott, please be aware that this question has already been asked and answered. Thank you

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

2002 Harley... | Answered on Jun 01, 2015


Hi Scott, first when checking anything in the starter circuit you must make sure the battery connections are clean and tight especially the negative cable at both ends and has a 12.5 volt or better charge. It must not fall below 9 volts during the cranking procedure with a volt meter hooked up. If it does fall below 9 volts do a proper load test on the battery and replace if necessary. Second replace the starter relay cheap $6 and make sure it's well grounded and getting 11.5 volts or better to activate. Third remove the back cover of the solenoid and de-arc/refurbish the contact plate and shoes making sure they are tight. If it still chatters replace the solenoid. Good luck

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

2002 Harley... | Answered on Jun 01, 2015


Hi Riccardo_tag, popping, coughing, spitting, or backfiring through the carburator or induction module can be caused by air getting sucked in combustion chamber do bad intake seals leaking. Leaking exhaust gaskets can also be suspect. Remove air cleaner and backing plate, while engine is idling spray WD-40 or Brake Kleen around intake manifold to head area, if RPM's increase you have an intake leak and seals need to be replaced, also spark plugs will be burning whiter than normal. Good luck

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

2002 Harley... | Answered on Jun 01, 2015


Hi Telesia78, and the usual suspects are:
1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition or leaking.
3. Spark plug gap to close or to wide.
4. Faulty ignition coil, module and or sensor.
5. Battery nearly discharged.
6. Damaged wire or loose connections at battery terminals,
ignition coil, or plug between ignition sensor and module.
7. Intermittent short circuit due to damaged wire insulation.
8. Water or dirt in fuel system, carburetor or filter.
9. Fuel tank vent system plugged or carburetor vent line closed off.
10. Carburetor controls misadjusted.
11. Damaged carburetor.
12. Loose or dirty ignition module connector at crankcase.
13. Faulty MAP, CKP, and or CMP sensors.
14. Incorrect valve timing.
15. Weak or broken valve springs.
16. Damage intake or exhaust vale.
For a prime suspect please visit website below and good luck:
Harley Davidson Sportster error codes and how to access them

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

2002 Harley... | Answered on Jun 01, 2015


Hi Michael, for more information on your question please visit the websites below and good luck:
Delboy Garage Harley Sportster Clutch Adjustment

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


2002 Harley... | Answered on Jun 01, 2015


Hi Anonymous, for a free wiring diagram please visit the website below and good luck.
Harley Davidson Wiring Diagrams and Schematics

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

2002 Harley... | Answered on Jun 01, 2015


Hi Anonymous, if you have a carburator the usual suspects are:
1. Damaged or restricted fuel tank venting system (gas cap).
2. Inlet system air leak.
3. Vacuum piston malfunction.
4. Accelerator pump leaking or no output.
5. Plugged bowl vent.
6. Fuel level (float chamber) too low.
7. Restriccted fuel supply passages.
8. Plugged jets or passages.
9. Worn or damaged needle or needle jet.
10. Enrichner valve not seated or leaking.
Good luck

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

2002 Harley... | Answered on May 31, 2015


Hi Denis992, perform the following tests:
1. Fill acid type batteries to proper levels.
2. Charge battery overnight at 1-2 amps you need 12.5 volts or better after charging.
3. Hook up battery positive cable, then with your multimeter on the milliamp scale connect one lead to the negative battery post and the other lead to the ground cable. Meter should read 3 milliamps or less, 10 milliamps with a radio, 15 milliamps with radio and CB. If your meter reads higher you need to isolate the circuit by pulling fuses and circuit breakers one at a time and observe meter for drop in aprerage then get out your test light and track down the short in that circuit.
3. Make sure all connections are clean and tight especially the negative cable at both ends.
4. Hook up volt meter to battery and start engine, if meter falls below 9.5 v while cranking replace battery.
5. With engine running at 3600 RPM battery should read 14.3-14.7 volts if not continue tests.
6. Unplug voltage regulator from alternator at crankcase by front of primary cover.
7. To test voltage regulator go to: https://www.youtube.com/watch?v=F8EjV0IjW9Q
8. With ohm meter, one lead grounded, touch alternator pin meter should read infinity, if not replace stator.
9. With ohm meter, both leads touching alternator pins meter should read 0.1 to 0.2 ohms on 1989 and later models. 0.2 to 0.4 ohms 1988 and earlier models, if not replace stator.
10. With volt meter set on AC scale, both leads touching alternator pins meter should read
16 to 20 volts AC for every 1000 RPM'S 1989 and later and 19 to 26 volts AC for every 1000 RPMS. If not replace rotor.
17. For a free wiring diagram please visit the website below and good luck.
Harley Davidson Wiring Diagrams and Schematics

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

2002 Harley... | Answered on May 31, 2015


Hi Andre, for more information on your question please visit the websites below and good luck:
Delboy Garage Harley Sportster Clutch Adjustment

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


2002 Harley... | Answered on May 31, 2015

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