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Sportster Motorcycle General Discussion and Problems For discussing problems about your Sportster motorcycle that don't fit anywhere else.

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  #1  
Old 12th June 2010
kramerb76 kramerb76 is offline
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Default 03 sportster dies and wont start when hot.

Ok having a problem with an 03 1200 Sportster not wanting to start when it is hot. Any help would be greatly appreciated.
Little history, bike is stock as far as I can tell. Went out for a ride last week about 15-20 mins and had dinner. Came out about 45 mins later (it was sitting in the sun) and wouldn't start. Got a new battery yesterday and was riding about 30 mins on side streets when it started to sputter like it was out of gas, pulled over and wouldn't start for about 30 mins. once I got it started to limp it home and it died again, this time wouldn't start for about an hour. So I started it up today and let it run then went around the block a couple of times, got home and tried to re-start it about 2 mins later and it just cranks and backfires. Pulled the rear cylinder plug and cranked it and there is spark (dont know how big its supposed to be but was there), correction just pulled both plugs and held to the cylinder and front one sparked once and then nothing on either after that. If it is cold it starts after 1 or two turns. Tried to heat the coil with a blowdryer and it never died. Trying to figure out if its the ignition module or fuel problem. Dont know how to check for fuel. Also tried removing the gas cap and trying to start to no avail. Only thing I have had done is my shop adjust the mixture on the card to get rid of the idle "farts" when I first got it. Any help would be greatly appreciated.
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  #2  
Old 13th June 2010
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How long did you hold the hair dryer on the ignition module? I had the same problem, same symptoms etc last summer on my '99 and it was the ignition module. I had to hold the hair dryer on the module with the bike running for about 5-10 minutes, all the while intermittently revving the engine and as you start to create load on the module (ie revving the engine) that's when it started to missfire (sputtering and sounds like its running out of gas). The fact that you were not getting a spark at the plug after that initial one also points that its an ignition problem. I would try the hair dryer a little longer, and also pick up a can of compressed air (like keyboard duster at office max) and once engine dies, spray this condensed air on the module which will cool it down. If it fires right back up, that's your problem. Good luck!
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  #3  
Old 13th June 2010
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ive had this problem... your ignition module is going out. replace it with a stock one if you dont want any headaches.... also go ahead and delete the bank angle sensor while your at it... it usually craps out right after the ignition... just ground the green wire with the white stripe coming from the ignition to delete the bank angle sensor..
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  #4  
Old 13th June 2010
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In all likelyhood its the module. The S/E replacement offers a higher rev limiter setting and a better ignition curve. You don't have to hit the limiter , but the improved curve is nice.
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  #5  
Old 13th June 2010
cm6 cm6 is offline
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Yes on ignition module. I to am a victim. Exact same problem
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  #6  
Old 13th June 2010
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I think you can recognize the pattern here....+1 on the module.
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  #7  
Old 13th June 2010
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Quote:
Originally Posted by kramerb76 View Post
... Pulled the rear cylinder plug and cranked it and there is spark (dont know how big its supposed to be but was there), correction just pulled both plugs and held to the cylinder and front one sparked once and then nothing on either after that. If it is cold it starts after 1 or two turns. Tried to heat the coil with a blowdryer and it never died...
You probably need:


If you're losing the spark, it's not fuel related. It could be a bad connection from module or coil. I've been through a few of the modules from overheating.
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  #8  
Old 15th June 2010
kramerb76 kramerb76 is offline
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Default

Quote:
Originally Posted by mistert923 View Post
How long did you hold the hair dryer on the ignition module? I had the same problem, same symptoms etc last summer on my '99 and it was the ignition module. I had to hold the hair dryer on the module with the bike running for about 5-10 minutes, all the while intermittently revving the engine and as you start to create load on the module (ie revving the engine) that's when it started to missfire (sputtering and sounds like its running out of gas). The fact that you were not getting a spark at the plug after that initial one also points that its an ignition problem. I would try the hair dryer a little longer, and also pick up a can of compressed air (like keyboard duster at office max) and once engine dies, spray this condensed air on the module which will cool it down. If it fires right back up, that's your problem. Good luck!
Want to make sure I was heating the same part. I held the hair dryer up to the coil that is behind the downtubes where the spark pulgs come from, also tried to cool it with compressed air and still nothing. Do I need to do the same thing to the Ignition Module (right side of engine under a rivetted cover and used to set timing)? want to make sure I am talking about the same parts. That is what I was leaning towards.
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  #9  
Old 15th June 2010
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You were heating the ignition coil. The ignition module (behind the riveted cover) is the part that is prone to failure due to excessive heat inside the nose cone. Drill out the rivets with a small bit, then you can tap the holes and replace the rivets with small allen bolts or screws.
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  #10  
Old 15th June 2010
kramerb76 kramerb76 is offline
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Thats what i thought. Thank you gonna try that.
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