(My First Rebuild) How do I connect the Main Wiring Harness 03 XLH 883 sportster

SOURCE: starter not always turning motor

Possible solution. You probably know that harleys, unlike almost all the others used a bendix type to shove the starter motor's gears into engagement with the starter clutch. Since you replace the solenoid, the thing that pushes the gears into engagement; the battery, that would push the starter motor if the gears were in engaagement; and the starter motor, which would turn the ring gear if it was in engagement. So wht's left? Unfortunately it sound like it might be the teeth on either the ring gear or the bendix gear, probably the ring gear as it was notoriously weak on iron sportys. Not a problem you want to try to fix at home unless blessed with tools, room and time.

SOURCE: Throttle to engine problem on 1993 Harley 883 Sportster

 You either need to lube the cables, or adjust them. You adjust the throttle to have a 16th to an 8th inch of freeplay with the bars like youre riding straight. You adjust the snap back with the bars fully to the right. As far as the motor shutting off , you need to use the enrichner ( they call it a choke) until it will idle on its own without rapping the throttle.  Also , your idle may be set too low on the carb. The adjustment is made at the idle speed screw , right behind the air cleaner. 

SOURCE: 93 HD Sportster 1200 will not start!

Have you tried to bypass the starter button/switch? Use a heavy jumper wire to go between the starter terminal and the positive battery terminal. Turn the key to "On" position, make sure "Run/Off" switch is turn on. Make sure bike is in neutral. I've started guys bikes with coat hangers before when they lost had trouble with the starter button. If the bike starter turns over, you'll at least have a place to start looking for the issue. Also you said you checked the battery, what was the voltage?

Testimonial: "Thanks for the info. I tried your solutions, but bike will still not start. Do not see any pinched wires. When you push the start button the ignition circit pops and then resets. Any other suggestions would be great. Thanks for all your help phinfanls13"

SOURCE: 2004 XLH 883 C SPORTSTER POPING THUR CARB. &

Usually, if you go up one size on the slow jet and readjust the idle mixture this solves the problem. I think you bike came equipped with a #42 slow jet. Go up to a #45, the next step richer. If you have not drilled and removed the "anti-tamper plug" that covers the idle mixture adjusting screw, do so. Be careful not to damage the screw as they are not available seperately from Harley. This will enrichen the low speed mixture just a bit.

You can also remove the needle from the slide and install a 3 mm flat washer that is about 0.020" thick on the needle to raise it up just a bit to enrichen the midrange just a bit.

Also, check your accelerator pump for proper operation.

Good Luck
Steve

SOURCE: 2000 HD Sportster XLH - makes "clicking" sound trying to start

Ok, If you are absolutely sure the battery is good, there are several possibilites. If the battery is over a year old, take it to an automotive parts store and ask them if they can load test it. They'll usually do this at no charge.

If the battery is good, the first problem could be in the starter relay. Look at the end of the starter from the right side of the bike. You'll see a plate on the end that is roughly shaped like a pentagon. Just above that plate is a plug with a single wire. Unplug this wire and use either a test light or a digital volt ohm meter to check for voltage when you press the starter button. If you do NOT have voltage and the clicking you are hearing is coming from under the seat, you probably need a starter relay.

If you have 12 volts on that wire, you're problem is in the starter. Disconnect the negative cable from your battery. Now, take the three small screws out of the back of the starter that holds the pentagon shaped plate on. Underneath the plate is a plunger and a spring. Remove these parts and look at the copper contacts on either side of the solenoid and on the plunger. If they are burned badly, you need to replace them. You can get the parts through an aftermarket supplier and they are not very difficult to replace. Usually, it can be done without removing the starter. Simply replace the contacts and a new plunger comes with the parts kit. Reassemble the starter, reconnect the battery cable, and you should be ready to go.

Good Luck
Steve