Specs: 2003 HD Sporty 883C, hyper-charger a/c, aftermarket pipes.

Note: A couple tanks of gas before this problem started I almost ran it out of gas. A tank later I filled up in the middle of no where with the worst gas I ever got.

Problem: A couple weeks ago my sporty started sputtering at stop lights/signs and almost stalling. A few days later it started stalling and a day later it started stalling randomly while I rode it. I would have to wait about 5-10 minutes and it would start up again. I could ride it for another few minutes and it would stall again. Repeat the process over and over... My first thought was carb so my mechanic buddy took it apart to clean it and it wasn't too bad. He put it back on and we went from there. My second thought was ignition module. After reading up on it on these forums that seemed to be the sure problem. I replaced that yesterday ($255 OEM). The sporty starts up fine and runs without stalling until I put a load on it and it will shut off. Seemed to be a timing issue so we worked that out. When sitting in neutral, I can start the bike and throttle it no problem. It doesn't sound like it did before we adjusted the timing. Now when I put it in gear and try to ride it I get to the end of my driveway and it sputters and spits black smoke. It doesn't shut off but I lose power. The black smoke indicates that it's running rich??? So I'm back to a carburetor problem at this point right???

I'm already missing Laconia Bike Week because of this... I don't want to miss the HD Rendezvous next week. PLEASE HELP HAHA!

Thanks. Zach

 

Did you clean the pet-*** screen?

 

Yes, the screen is clean. I wish that was the solution! haha

 

Is the black smoke coming from both pipes or just one?

 

It looked like the smoke was coming out of both.

 

If it's both, I would look again at the carb. If it's one pipe, you could have an ignition problem.

 

I just replaced the ignition module and will be doing the ignition coil today... also doing new plugs today. I'm hoping I don't have to re-jet. I've owned this bike for almost a year and haven't changed the intake or pipes. So it shouldn't be a jet issue... right?

 

Nope, the jet size shouldn't need to be changed if it was running good before.
The coil is a reasonable possibility.
Be sure and gap the plugs @ .040".

 

Do you know anything about the timing of the ignition module. I don't have pictures but I took the timing cover off (The small 3 inch cover with the 5speed on it) and then I unscrewed the inner cover to get to the module. I replaced the module and put both covers back on. I heard that the placement of that inner cover has to do with the timing of the module. I marked it and put it back together how I found it but I'm still not sure.

I spoke to a mechanic down the street and he said to re-jet the carburetor instead of replacing the coil but that doesn't make since to me since this issue only started recently. I think there is an adjustment off somewhere and I have already spent a bunch of money trying to chase this thing down...

 

Sorry, I don't any manuals for the pre 04 Sporty and only limited experience with ignition timing on them.
The Sporty was completely changed in 2004.

Maybe someone else will chime in.