2002 Harley Davidson XL 1200 S Sportster Sport Logo
Joe H. Posted on Aug 18, 2010
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2002 sportster 12 evolution,doesnt keep spark to plugs, the 02 model is suposed to have the ignition module under the side plate.i think its under the seat.have cleaned the battery cables replaced the coil and checked the wires at the kill switch. any sugestions without just paying $235.00 to hope its the right part

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  • Master 4,565 Answers
  • Posted on Aug 19, 2010
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Harley has been moving things around since 2000 and it makes life tough for people that do what I do. Try to fix bikes over a computer. I used to tell people that I couldn't fix a bike over the phone. LOL

On your bike, I don't know of any way to test the ignition module. Harley has a way to do it if you use a meter exactly like the one they use but I have never seen one of their meters.

Before you spend a lot of money on a new unit, first check your ground on the unit. Check the plug on the unit. It's also got a cam position sensor in the timer cavity on the left side of the engine as best as I can remember. This part is a lot less expensive but I'd rather solve the problem and replace a part rather than replace parts until I solved the problem.

I'd go to the auto parts store and buy a set of Autolite 4164 spark plugs and try those. The two best brands of plugs in my opinion are Autolite's and NGK's. Not those expensive copper or titanium or whatever they are plugs. Those things are made of auto engines that are running a lot hotter ignition system than your Harley is running. In an air cooled motorcycle, the cheaper the plug, the better they run. Don't waste money on the expensive plugs.

Try that, at least it's cheap. If it doesn't work, start checking connections. I'll say this, when a solid state ignition unit it working, it works. When one stops working it's usually for good. They very rarely stop then start back. Look for that loose connection.

Good Luck
Steve

Testimonial: "Steve, Thanks man, you have filled in the spot for me I'll go over it all again...im sure the plugs are ok,bike runs great, aside from loosing fire."

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No spark 2002 Harley Davidson XL 1200 S Sportster Sport

Hi, Logan and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 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 batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at the ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
6. Faulty ignition coil or electronic control module.
7. Faulty pulse coil.
8. Faulty CKP, CMP, or BAS sensor.
9. Faulty ignition switch.
10. Faulty run/off switch
11. Tilt sensor needs a reset.
12. Security alarm failing to disarm needs reset
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 [email protected]. Good luck and have a wonderful day.
https://www.hdforums.com/forum/ignition-tuner-ecm-fuel-injection/628252-2001-sporty-no-spark-at-plugs.html
http://www.mediafire.com/file/fjn2ksqmw7rci0f/2002_Harley_Sportster_Service_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://www.harley-davidson.com/us/en/owners/motorcycle-maintenance.html
https://www.6ya.com/how-6ya-works to speak to me personally.
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