20 Most Recent 2004 Harley Davidson XL 883 Sportster Questions & Answers


Hi, Brian 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.youtube.com/watch?v=DaVSpUYiW2k
http://www.mediafire.com/file/l6yf9cj68rct746/2004+Harley+Sportster+Service+manual.pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.carlsalter.com/mcpdf/Harley%20Davidson-1970-03%20Owners%20Manual.pdf
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2004 Harley... | Answered on Jan 28, 2019



P0262 = FRONT INJECTOR HIGH

Possible causes
- Dirty Fuel Injector 1
- Faulty Fuel Injector 1
- Plugged Fuel Injector 1
- Fuel injector 1 harness is open or shorted
- Fuel injector 1 circuit poor electrical connection
Tech notes
Clogged or partially clogged fuel injector can cause this code. Start by performing an injector flush before replacing the injector.
Possible symptoms
- Engine Light ON (or Service Engine Soon Warning Light)
- Engine Misfire
- Engine Run Rough
- Low MPG
P0262 Description
Code P0262 is triggered when the Engine Control Module (ECM) detects a low voltage in the Fuel Injector 1 Circuit. During normal conditions theECMturns the Fuel Injectors ON and OFF in the Fuel Injection System.

2004 Harley... | Answered on Dec 28, 2018


Hi, Dennis you turn on the ignition switch press the starter button and all you get is the dreaded "CLICK" or "CLUNK" now before testing any electrical component in the Starter System 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 if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. Depending on battery voltage starter relays and starter solenoids can make the same noise when you hit the starter button. You can easily determine which one is at fault by the following two simple tests:
STARTER RELAY- place your thumb and index finger on the starter relay and press the starter button, if you feel the click then the relay is faulty and needs to be replaced.
STARTER SOLENOID- bridge the positive and negative poles of the solenoid with a small screwdriver if you get a loud clunk then the solenoid needs to be rebuilt or replaced as necessary. If the engine turns over then replace the starter relay otherwise the usual suspects for a faulty starter solenoid are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, must be 12.5 volts or better, voltage from the battery to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid must not drop more than 1/2 volt of battery voltage.
4. Disconnect spark plug cables, with a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 9.6 volts DC. If the voltage is below 9.6 the battery is faulty and must be replaced. I "HIGHLY" recommend a maintenance free AGM battery typically they have more amperage for cranking.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohmmeter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buying a new 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.
Won start clicking noise The Sportster and Buell Motorcycle Forum The...
2004 Harley Sportster Service manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
2005 Harley Davidson Sportster 883 Owner Manual
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2004 Harley... | Answered on Jun 17, 2018


Hi, Anonymous the correct spark plug for your Harley-Davidson model is HD 6R12 and gapped at .040". With a dab of Anti-Seize on the threads install using an applied torque of 15 ft lbs. 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 Sportster Evolution Spark Plugs Replacement
Harley Davidson 2005 Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://mybikemanuals.com/harley-davidson/2005-harley-davidson-owners-manuals
Instant Tech Relief To speak to me personally absolutely "FREE"

2004 Harley... | Answered on Sep 21, 2017


Hi, Real you can't timing is controlled by the ICM 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 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.
http://xlforum.net/vbportal/forums/archive/index.php/t-34308.html
Harley Davidson 2005 Sportster Service Manual
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://mybikemanuals.com/harley-davidson/2005-harley-davidson-owners-manuals
Instant Tech Relief To speak to me personally absolutely "FREE"

2004 Harley... | Answered on Jul 16, 2017


Hi, Stephen for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Best carb for an 883 Harley Davidson Forums
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"

2004 Harley... | Answered on Feb 20, 2017


Hi Thegrimmycre, for more information about your question, please visit the websites below. Good luck and have nice day. xlch@mail.com 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

2004 Harley... | Answered on Jul 27, 2015


Hi Mattrambish, 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

2004 Harley... | Answered on Jun 17, 2015


Hi Joseph, 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.

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

2004 Harley... | Answered on Jun 17, 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

2004 Harley... | Answered on Jun 17, 2015


Hi Whirledofcus, you may need a carbuerator rebuild, for more information about your question please visit the website below. Good luck and have nice day.
Harley Davidson CV Carburator rebuild and float adjustment ep 18 eng Roma...

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


2004 Harley... | Answered on Jun 17, 2015


Hi Anonymous, if you mean the nuetral light is not coming on then check the continuity of the nuetral switch located on top of the transmission. Good luck

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

2004 Harley... | Answered on May 19, 2015


Hi Kim, what's wrong with the fuel injector on your sportster?

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

2004 Harley... | Answered on May 19, 2015


Hi William, try checking continuity on your rear brake light switch. Good luck

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

2004 Harley... | Answered on May 19, 2015


Hi Anonymous, check the accelerator pump on your carb for proper function. Good luck

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

2004 Harley... | Answered on May 19, 2015


Hi Vandenscott, for more information on your question please visit the websites below and good luck: https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-8#q=2004+xl883+Camshaft+positioning+and+timing+picture

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

2004 Harley... | Answered on May 19, 2015


Hi Rhamilton, I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck. 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

2004 Harley... | Answered on May 19, 2015


Hi Anonymous, I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck. 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

2004 Harley... | Answered on May 19, 2015


Hi Josephniffen, you have a dead/hard short. Should be easy to find with test light after you check your battery for clean and tight connections. 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

2004 Harley... | Answered on May 19, 2015

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