Harley Davidson XLH Sportster 883 Hugger - Answered Questions & Fixed Issues

kinda sounds like you broke a ring or crank case vent plugged

Question edited for clarity and all the typos :>D Question moved to make / model category. Clutch replacement. My guess is something not right. https://www.google.com/search?q=1986+harley+davidson+sportster+883+replace+clutch+plates Service manual

1986-03 Sportster XL XLH Service Manual

https://www.ratbikeservice.com > dwnld > 1986-03 ... PDF This detailed and comprehensive manual covers. 1986-2003 XL/XLH Sportster models. The text provides complete information on maintenance, tune-up, repair and. 638 pages

On most vehicles rocker covers are not normally bolted down that hard. Install the bolts by hand until finger tight then tighten in sequence a Quarter turn at a time until you get to 20 Ft/lbs and NOT tighter. Rocker covers are not normally exposed to full oil pressure so don't need to be a high torque setting. I often go to 15 Ft/lbs first and run the vehicle for one or two miles to check for leaks. That gives me that extra 5 Ft/lbs to avoid over tightening bolts.

I don't know the answer to your question but it would be wise to obtain a wiring diagram so you can see the function of the wires you joined together and can have a more educated guess as to the source of the popping.

You put the spring plate on first (after putting on all the clutch disks) with it being held in the compressed state. Then you insert the snap ring into the grooves in the center of the clutch. Then you can re leave the pressure of the compressed spring plate. The snap ring is used to keep the spring plate under pressure at all times in normal operation.

Yes not in the hand peace but on the carb/throttle body. They place it there as a safety shut off if a cable was to brake.

I would check the needle valve in the carburetor to confirm it does shut off, float level, and such in the carb. Doesn't sound like timing to me.

speed sensor locale on a 2003 sprotster(whoops) sportster is pretty much the same as where it is on the 2004 storpsert - the same question about the location was asked a few lines earlier...scroll up!

See if bulb sockets are corroded, check blinker unit & check all electrical connections & grounds.

Backfire through carb often means timing too advanced.

please check the fuses and then the bulb

Making More Horsepower

1. Full throttle only, on hot days, at low rpm. Carburetor is a bit lean in needle seat or main jet. Not too serious. We all have this problem sometimes.
2. Full throttle only, on hot days, at mid or high rpm. Carburetor is a bit lean in needle seat or main jet. This is more serious. Get on this problem soon.
3. Happens even while cruising at a constant speed. Carburetion is way too lean, or compression ratio is too high, or the gas you just bought is Tijuana special, cut with #2 diesel. Pull off the road, call for a trailer. This is big time serious.

Black smoke on full throttle acceleration. Main jet is too rich. Grey smoke on full throttle acceleration. Bad valve guide seals, or bad rings. The engine was mis-assembled. Grey smoke when you start the engine, particularly when cold. Bad valve guide seals. The engine was mis-assembled. Ticking sound which goes faster and slower as the engine does.

1. Bad spark plug connection to ignition coil (pray this is it).
2. Stuck lifter.
3. Improper valve to valve clearance, or improper valve to piston clearance.

Engine misses at idle or full throttle acceleration. Bad connection from ignition coils to spark plugs. Truly crummy gas mileage, as in less than 40 when cruising, or less than 35 around town.

1. Too much cam duration. You're blowing gas out your exhaust pipes.
2. Carburetor is way too rich, especially in the midrange.
3. Accelerator pump on carburetor is adjusted too aggressively.

Please rephrase your question, and provide a picture of what you're talking about, if you are able. Your question makes no sense as posted.

My question is why you want to fool around with the timing? Unless you took something apart, you can't adjust the timing.

I would first suspect an air leak around the manifold. If you are sure the cables are adjusted correctly, when you roll back the throttle you will close the butterfly on the carburetor. This in turn should put the carburetor in idle mode. As an engine needs air and fuel to rev up, your problem lies somewhere in this area. Check the operation of the piston in the carburetor making sure it is totally free to move up and down as this is a CV carburetor (assuming your bike is stock) as if the piston is sticking, this could cause your problem. Check for a broken butterfly shaft as these can break in the middle and not be evident. Check for air leaks by spraying WD40 around the manifold seals while engine is running and if engine changes revs then you have an air leak.

There is one circuit breaker, a 30 amp one, that feeds the complete bike, and it is connected between the ignition switch and the starter motor. The circuit breaker should have 0 ohms between the two studs when o/k and can be tested with an ohm meter. To see if it is working, you really need a variable current source that is metered and that can exceed the rating of the circuit breaker and test accordingly. Another simply way is to short the ignition switch to ground and the breaker should click open. Remove the short and after a short while, the breaker should click closed. Not really recommended and don't know why you would want to do this as it will stress the breaker unnecessarily. If ohm meter shows it ok then leave it alone. Another way is to simply check for voltage at ignition switch. If 12 volts present, then breaker ok.

Does your bike have a coil? Check your fuses too.

Maybe this would help and get the HD factory manual also. http://www.harleydavidsonmaintenance.com/sportster-transmission-oil.html

Do an oil pressure test with a know good oil pressure tester gauge. If really low etc could be thinned out/contaminated/old oil and/or defective pressure release valve OR more.

Rear lighting connector is a 6-place Multilock connector under the seat Has anyone doen ANYTHING to the bike recently, EVER??? Post comments and we will go from there