20 Most Recent 2002 Harley Davidson XL Sportster 883 Questions & Answers


Hi, Vernon 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.
Harley Davidson Starter Replacement Install Starter Clutch FIX Complete...
http://www.mediafire.com/file/nc0vlqn31bb4477/70-03_Harley_Sportster_Service_Manual.pdf/file
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

2002 Harley... | Answered on Jun 14, 2019


Hi John, and the usual suspects are:
1. Severely discharged or damaged battery.
2. Loose, corroded or broken battery cable.
3. Alternator not charging or below normal rates.
4. Failed ignition coil, ignition/electronic module.
5. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor.
6. Faulty ignition switch.
7. Water or dirt in fuel system, carburetor or filter.
8. Fuel tank vent system plugged or gas cap not venting.
9. Fuel tank empty.
10. Fuel valve vacuum line broken or carburator vent line closed off.
11. Restricted, blocked or kinked fuel line.
12. Failed fuel pump, pressure regulator and or fuel injectors.
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 Apr 05, 2019


Hi, 14jbworkingclass 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.
https://www.google.com/search?q=2002+Harley+Davidson+XL+Sportster+883+vacuum+line+routing&tbm=isch&source=univ&sa=X&ved=2ahUKEwj__YLgweLgAhXvtlkKHZbODskQsAR6BAgCEAE&biw=1440&bih=757
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
Instant Repair Help over the Phone To speak to me personally $6

2002 Harley... | Answered on Mar 02, 2019


Hi, AndreaI would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
1. Bearings---SCREECH
2. Belts---CHIRP
3. Brake Rotors---BUZZ
4. Rear Chains---RATTLE
5. Cam Chains---CLICKIT
6. Clutches---CHATTER
7. Cylinders---PING
8. Fairing Panels---WHISTLE
9. Fronk Forks---Plunk
10. Gears---WHINE
11. Head Gasket---HISS
12. Hydraulic Lifters---TAP
13. Pistons---SLAP
14. Radiators---GURGLE
15. Rear Chains---RATTLE
16. Rear Shocks---SQUEAK
17. Relays---CLICK&BUZZ
18. Shaft Drives---WHIRR
19. Shifting Trans---CLUNK
20. Solid Lifters---TICK
21. Starters---CLICK
22. Connecting Rods Go---KNOCK-KNOCK---who's there, it's me "*****"
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.
Knocking Noise in Primary
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 Sep 29, 2017


Hi, Darrin fuse and circuit breaker location are as follows:
SPORTSTER-Underneath the seat or behind the left side panel or inside the headlight bucket.
SOFTAIL-Underneath the seat behind the battery or under the speedometer housing.
DYNA-Behind the left side panel.
TOURING-Under speedometer housing or left and right side panel.
Under the speedometer housing or inside the headlight bucket location is for mechanical circuit breakers only.
The following is an approximate timeline of Circuit Breakers and Fuses.
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 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.
sportster fuses
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

2002 Harley... | Answered on Jun 08, 2017


wires around the head stock for insulation damage and shorting out

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


Hi, Jack before inspecting your points you will need to remove the spark plugs and timing hole plug if you have electric start only, you will need to get the rear wheel off the ground about 2 inches and put the bike in first gear for bumping the engine over. Refer to your service manual for the proper timing marks on your flywheel for your particular year and model as Harley made several changes over the years. Remove the points plate cover, the 2 points plate stand-off studs, the points and points plate, the center points cam bolt, and finally, the mechanical advance mechanism paying close attention to the locator pin on the back side of the advance mechanism and the corresponding machined slot on the end of the camshaft that it fits into. Inspect the advance mechanism carefully look for weak, almost or broken springs, worn advance pins, and wobbly weights due to egg-shaped mounting holes, replace defective parts as necessary, lubricate flyweights mounting holes/pins/springs with a small shot of WD-40. If you have any doubts of the integrity of the advance mechanism replace it with a new one. Next carefully inspect the points look for pitted contact surfaces and refurbish with a point file or 220 grit or coarser folded sandpaper, if necessary, inspect the rubbing block for excessive wear if in doubt about condition replace with new points and new condenser, I recommend Blue Streak Points Kit. Carefully install advance mechanism, points cam with flat side behind the limit pin, and center bolt tighten to 70-inch pounds. Install points plate, points, and condenser, snug stand-off screws and using an ice pick or similar device stake the points plate on the edges in three different spots, this procedure is very important as it will keep the plate from becoming eccentric during timing procedure. Next bump the engine over until the points rubbing block is on either the fat or skinny cam lobe and insert a .018" flat blade feeler gauge in between the points slightly loosen the points adjusting screw and set the point cap so you can remove the gauge with a slight drag, bump the engine over to the other cam lobe and measure what that gap is because they are supposed to be the same, but rarely are. Now comes a little finesse on your part you need to bump the engine over to the lobe with the widest gap on the points and take a measurement in between the points forget about the .018", using a small hammer and a flat punch lightly tap the center bolt from the top once this will lower the cam lobe closing the point gap and raise the other cam lobe thus opening the points slightly more, then bump the engine over again to the other lobe a take another measurement, you need to get cam lobe measurements identical to within .004" or better this is "VERY" important as it determines when the front and rear cylinder fire. When you get the measurements as identical as possible example .012" on one lobe and .010" on the other adjust your points on any lobe to 018" and lock it down. All this may seem petty but I can assure you it makes all the difference in the world when it comes to starting, idling, and performance, trust me. Now that you have the spark plugs firing correctly to each cylinder you need to statically adjust when they fire, to do this get the front cylinder advance timing mark dead center in the timing hole window by bumping the engine with the rear wheel, at the top of the left crankcase for Big Twins the right crankcase side for Sportsters, spray Brake Kleen on the mark to remove any oil film let dry then paint the flywheel and timing mark with red nail polish and let dry, this will help you greatly when it comes time to use a timing light. Next bump the engine slowly until the top dead center mark is in the timing hole dead center, loosen the standoff studs and rotate the points plate until the instant the points start to open, use a test light for accuracy clip the line to ground and wedge the point of the light to the electrical connector on the points turn on the ignition and the kill switch to run, when the light comes on the points have started to open snug down one stand-off stud. Next turn off the ignition and put the bike back in neutral, lower the rear wheel back on the ground, drain the oil tank into a clean container, replace 16 oz. of the oil, this is plenty to lubricate the engine and limit the oil and breather blast that comes out of the timing hole when using a light. Next use a sandwich bag or Saran Wrap and a rubber band over the end of the timing light lens, connect the timing light to the front cylinder spark plug with the bike in the upright position start the engine and let idle for 1 minute, set RPM'S to 2,000 have someone remove the timing plug being careful not to be in direct line of breather/oil mist spray, hold timing light directly in front of the hole you should be able to see the nail polish front cylinder advance timing mark, if not loosen the stand-off stud and adjust the timing plate until the red nail polish come into view, you want the mark dead center in the hole, when you get that position lock down both timing plate standoff studs and shut off engine, replace timing hole plug and remaining engine oil, adjust idle to 1,000 RPM and if necessary air fuel mixture screw on carburetor. 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 xlch@mail.com. Good luck and have nice a day.

Ironhead Sportster points and timing

Owner Manuals Harley Davidson USA

http://www.stcharlesharleydavidson.com/OEMpartfinder.htm

Harley Davidson Manuals Mark Workshop

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 Mar 02, 2016


Hi, Wayne the following applies to carbureted also fuel injected models and the usual suspects are:
1. Severely discharged or damaged battery, 9 volts or lower.
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, 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. Air/fuel mixture screw improperly adjusted.
10. Water or dirt in the fuel system, carburetor or filter.
11. Restricted, blocked or kinked fuel line.
12. Fuel tank empty.
13. Gas cap is not venting properly or fuel tank venting system blocked.
14. A failed fuel pump, pressure regulator and or fuel injectors.
15. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
16. Needle and seat stuck closed in the float bowl.
For more information about your issue, please visit the websites below, and for specific information or questions, please feel free to contact me at xlch@mail.com. Good luck and have a nice day.
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

2002 Harley... | Answered on Dec 26, 2015


Hi Brdbrwn, call, take a ride or trailer your bike over to your local dealers service/parts department, I'm sure they will be happy to take your Harley Davidson for a test ride if necessary/possible and offer professional advice and assistance concerning your issue. Good luck have a nice day.

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 26, 2015


Hi Ritterfamily, always check your instrument fuse before performing the next procedure, try cleaning your speed sensor located on top of the transmissions right side between the top cover and the chrome starter end cap on Twin Cams and on top of the engine case between the rear cylinder and the starter motor for Sportsters. Remove the the bolt that secures the sensor and pull it out of the transmission. Inspect sensor for obvious damage and repace if necessary. If sensor has no damage then wipe clean any obvious contamination like micro fiberous material with a clean rag and reinstall, torque bolt to 8 ft lbs. Next check the connector to the speedometer for correded, broken or loose pins/sockets. If your problems still exist try replacing your ignition relay if your year and model has one. Good luck and have nice day.

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 26, 2015


Hi Gstpierre302, for more information about your question please visit the websites below. Good luck and have nice day.
http://www.harley-davidson.com/app-content/service/isheets/-J05185.PDF

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 26, 2015


Hi Seanwbaker, 1998 and later Sportster models circuit breaker and fuses were located in an electrical bracket behind the starter relay and data link that was mounted behind the left side panel. 1997 and earlier circuit breakers only no fuses were located under the seat.
You need to get out your test light and find the short and start by making sure the battery has 12 volts or more and clean tight connections especially the ground cable at both ends. If your issues involves lights always check the bulbs for broken filiments and fuses first. Then start at the socket and work your way towards the handlebar switches checking each wiring harness connector for corroded, broken or loose pins and remember dielectric grease is your friend. Check the switches for continuity and work your way towards the ignition switch and check it for continuity. Keep working your way to the fuses and circuit breaker and finally the battery. For a free wiring diagram please visit the website below. Good luck and have nice day.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 26, 2015


Hi Voltaje480, call, take a ride or trailer your bike over to your local dealers service/parts department, I'm sure they will be happy to take your Harley Davidson for a test ride if necessary/possible and offer professional advice and assistance concerning your issue. Good luck have a nice day.

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 26, 2015


Hi Anonymous, could be a loose or faulty bulb or bad head light ground. Good kuck and have nice day.

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 26, 2015


Hi Anonymous, I'm sorry but I just loaned my listening ears to the lead technician at your local Harley Dealer so he could take your bike for a test ride and evaluate the noise. Good luck and have a nice day.

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 26, 2015


Hi Anonymous, and the usual suspects are:
1. Damaged or restricted fuel tank venting system.
2. Loose float bowl screws.
3. Damaged float bowl o-ring.
4. Improper fuel level in float bowl.
5. Worn or dirty inlet valve or seat.
6. Damaged or leaky float assembly.
7. Particle contamination in inlet fitting cavity.
8. Ethanol sludge, dirt, rust in bottom of fuel tank
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 26, 2015


Hi John, for more information about your question please visit the websites below. Good luck and have nice day.
Delboy Garage Harley Sportster Battery Replacement

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 26, 2015


Hi Anonymous, for more information about your question please visit the websites below. Good luck and have nice day.
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 26, 2015


Hi Cindy, for a free wiring diagram please visit the website below. Good luck and have nice day. 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 26, 2015

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