Harley-Davidson Sportster XL1200X Forty-Eight - Owner's Manual > Troubleshooting

Troubleshooting: General

The troubleshooting section of the Owner's Manual is a guide to diagnose problems. Read the service manual before performing any work. Improper repair and/or maintenance could result in death or serious injury.

Use the following checklists for troubleshooting. Carefully check each cause because more than one condition can cause trouble.

Engine

Starter Does Not Operate or Does Not Turn Engine Over

1. Engine OFF/RUN switch off.

2. Ignition switch off.

3. Discharged battery or loose or corroded connections (solenoid chatters).

4. Clutch lever not squeezed against handlebar or transmission not in neutral.

5. Jiffy stand not in retracted position (for models equipped with jiffy stand interlock).

6. Blown fuse.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fuel filter clogged.

3. Discharged battery or loose or damaged battery terminal connections.

4. Fouled spark plugs.

5. Spark plug cable connections loose or in bad condition and shorting.

6. Loose or corroded wire or cable connection at coil or battery.

7. Fuel pump inoperative.

8. Blown fuse.

Starts Hard

1. Spark plugs in bad condition, have improper gap or are partially fouled.

2. Spark plug cables in bad condition and leaking.

3. Battery nearly discharged.

4. Loose wire or cable connection at one of the battery terminals or at coil.

5. Engine oil too heavy (cold weather).

6. Fuel tank vent plugged or fuel line closed off, restricting fuel flow.

7. Water or dirt in fuel system or filter.

8. Fuel pump inoperative.

Starts But Runs Irregularly or Misses

1. Spark plugs in bad condition or partially fouled.

2. Spark plug cables in bad condition and leaking.

3. Spark plug gap too close or too wide.

4. Battery nearly discharged.

5. Damaged wire or loose connection at battery terminals or coils.

6. Intermittent short circuit due to damaged wire insulation.

7. Water or dirt in fuel system or filter.

8. Fuel vent system plugged. See dealer.

9. One or more injectors fouled.

A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich.

2. Incorrect spark plug for service

Pre-ignition or Detonation (Knocks or Pings)

1. Incorrect fuel.

2. Incorrect spark plug for service

Overheats

1. Insufficient oil supply or oil not circulating.

2. Heavy carbon deposit from lugging engine. See dealer.

3. Insufficient air flow over cylinder heads during extended periods of idling or parade duty.

Excessive Vibration

1. Rear fork pivot shaft loose. See dealer.

2. Front engine mounting bolts loose. See dealer.

3. Front chain or links tight as a result of insufficient lubrication or belt badly worn.

4. Engine to transmission mounting bolts loose (applicable models). See dealer.

5. Damaged frame. See dealer.

6. Wheels and/or tires damaged. See dealer.

7. Vehicle not properly aligned. See dealer.

Engine Oil Not Circulating (Oil Pressure Lamp Lit)

1. Insufficient or diluted oil supply.

2. Oil feed clogged with ice and sludge in freezing weather.

3. Grounded oil signal switch wire or faulty signal switch. See dealer.

4. Damaged or improperly installed check valve. See dealer.

5. Oil pump problem. See dealer.

Electrical System

Alternator Does Not Charge

1. Regulator not grounded. See dealer.

2. Engine ground wire loose or damaged. See dealer.

3. Loose or damaged wires in charging circuit. See dealer.

Alternator Charge Rate is Below Normal

1. Weak battery.

2. Excessive use of add-on accessories.

3. Loose or corroded connections.

4. Extensive periods of idling or low speed riding.

Transmission

Transmission Shifts Hard

1. Bent shifter rod. See dealer.

Transmission Jumps Out of Gear

1. Worn shifter dogs in transmission. See dealer.

Clutch Slips

1. Clutch controls improperly adjusted. See dealer.

2. Worn friction discs. See dealer.

3. Insufficient clutch spring tension. See dealer.

Clutch Drags or Does Not Release

1. Clutch controls improperly adjusted. See dealer.

2. Primary chaincase overfilled.

3. Clutch discs warped. See dealer.

Clutch Chatters

1. Friction discs or steel discs worn or warped. See dealer.

Brakes

Brakes Do Not Hold Normally

1. Master cylinder low on fluid. See dealer.

2. Brake line contains air bubbles. See dealer.

3. Master cylinder piston worn. See dealer.

4. Brake pads contaminated with grease or oil. See dealer.

5. Brake pads badly worn. See dealer.

6. Brake disc badly worn or warped. See dealer.

7. Brake fades because of heat build up. Excessive braking or brake pads dragging. See dealer.

8. Brake drags. Insufficient hand lever free play. See dealer.

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