Hello. This is my first question on here. I have an 03 sportster xl1200c. About two weeks ago, it started running bad.

Out of nowhere, it began to sputter and run horrible while in downtown Ft. Worth. It would act like there was no gas, but the tank was full. Then it would die, sometimes running fine for a mile then dying. I parked it and put in octane booster because I suspected bad gas. Ran fine for about 10 miles, then sputtered a couple times but did not die.

The next day, it sputtered after riding for about 5 miles so I put more octane booster in, and no solution. It kept doing this after two more tanks, dying frequently on the highway while I had to pull over. I then suspected it wasn't bad gas, so I changed the spark plugs, placed a new o ring gasket on the carb, took the tank off, drained gas and checked the filter which was fine. Checked battery connections. Checked all other connections, fine. Rode great for about 30-50 miles that night, then began to sputter again.

Took it home and ran seafoam through it to clean out the carb. Rode down the street and pipes caught on fire from so much backfiring. Got it home, pulled jets, looked fine. Rebuilt carb. Cleaned everything. Ran it down the highway, was fine for about 4 miles then sputtering again. Got into town, no sputtering. It seems at times when I rolled on the gas heavy it would die out. Checked the coil and ignition module, everything to specs.

Please help!

 

Sounds likea fuel problem, also sounds like you have covered all the bases on that. Did you check for any kinked fuel lines when you had it apart. You could check resistance in the coil before you ride and then when starts acting up and see if they are different. Not real sure on what needs to be done to check the ignition module though. Sorry not much help, keep us posted and let us know when you figure it out.

 

check your carb float, it might be sticking, or have a tiny hole in it.

 

When i take the air cleaner off and give throttle, plenty of fuel flows to it, changed the line from petcock to carb and looks fine. I couldn't find any vac. leaks either.

Where could the hole be on the float?

Also, it seems weird that it runs fine, then doesn't. Does anyone know the traditional signs of a bad ignition module? I would hate to spend $200 on a new setup and not need it.

 

Mine did the exact same thing it wound up being the coil.

 

Update_ I just tried starting and won't even turn over now. Makes a fast paced clicking sound?

 

+1 The coil is a very high probability. Many times coils will fail only after getting hot, 15 - 30 minutes of operation. But before you buy a coil, make sure the coil wire connections are tight.

Edited.. Missed your last post, that's not the coil. Check battery cable connections at both ends.

 

Check your negative cable and where it attches to frame. Check for tightness and corrosion, I am thinking this could be the problem now that the bike won't turn over.

 

Just started with battery charger. Bike fine but still same problem with sputtering after riding down highway.

Is it easy to install a new coil? And, should I worry about timing?
Thanks all for the help!

 

It's relatively easy to install and no timing to worry about.