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  #1  
Old 22nd June 2018
Bob Bob is offline
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Question Spark Plugs

I have a 1995 Sportster Hugger 883 and for some unknown reason my spark plugs started going completely dead (kaput) not fouled but dead - will not spark under any condition, at about 25 to 30 miles. I have changed spark plug wires , coil and resistor plugs and no resistor plugs and wires. I also added an extra ground wire to the engine.
I am at a complete stand still of what to try next. I went to a Harley dealer in Johnson City TN and the only thing they recommended was running it on one of their test apparatus, for a high fee. Plus it is over 50 miles to their shop.
Any help would be greatly appreciated.

Bob
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Old 22nd June 2018
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Likely ignition module failure
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Old 22nd June 2018
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Sounds heat related. It would seem the only remaining suspects are the sensor or the electronic-ignition module. I would guess it’s the module.

Per the online fiche at https://shop.outpostalaska.com, the OEM module (32410-94A) is NLA. A google search for the part number returns some for $100-200 on ebay.

Questions:
- The spark returns after the engine has cooled down?
- Have you tried spraying the module with “cold spray” to see if that brings back your spark sooner?
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Old 23rd June 2018
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Good suggestions from RocketMan George and J Zinc.

Ignition Module Bypass Test
The ignition module closes the coil primary circuit to ground. Based upon a timed signal from the cam sensor, the module opens the primary circuit, causing the secondary (high voltage) winding to discharge through the plugs to ground.

To verify that wiring and other components (coil, plug wires, plugs) are OK, when a failed/failing ignition module (pre 04) is suspected, try this: Pull the coil wire (at the coil) to the module (not the 12VDC to the coil primary). If connectorized, pull the connector, then jumper 12 VDC to the + side of the coil.

Note: The coil has no actual polarity. + & - are irrelevant, but + denotes incoming voltage and – denotes side to be grounded through the module. In other words, do not ground the incoming voltage without the load/resistance of the coil

Ground the ignition module side of the coil (-), then remove ground, expecting one spark (plug out of head, in secondary wire, plug prong grounded). If done correctly and no spark, then the problem is NOT the module.
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  #5  
Old 23rd June 2018
Bob Bob is offline
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Thank you sportsterdoc. & Rocketman I will try your suggestions.

Bob
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  #6  
Old 23rd June 2018
Bob Bob is offline
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Thank you jzinko883 No I have not tried your suggestion but I have tested the dead spark plug by other methods and like I said the plug is dead.

Bob
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