I have a 99 Harley Sportster 1200. I rode it about an hour with no issues. When I stopped to fill it up I got my dash to light up, but no other power to headlights, etc. Some guys push started me and the engine kept sputtering. The dash would turn on and off and I didn't make it over 20 mph. I towed it back and found the ignition switch was loose so I replaced that. It still didn't solve the problem. When the wires are connected for the lights only the dash comes on, no lights, turn signals. The resistance on the regular/rectifier was slightly high so I replaced that. Still no luck. When I check continuity between the wires of the stator I only get continuity for the 2 wires in the one connection and not to the 3rd connection. Do these all need continuity? The battery was charged when I checked it, 12.6v so I didn't think it was a charging problem. Could this all be the stator or should I check the starter and possibly chase the wires through the headlight and push start?

 

I would unbolt , clean and re tighten any Earths first of all just in case one has corroded or shaken loose .

 

Positive connections are just as important as ground connections.

Clean all battery cable connections.

 

It's amazing how people fixate on grounds. Takes two to tango.
There should be no reading to ground on stator wires, but I would not bother with charging system yet.
Stator produces ack come of volt reg DC to battery. Not sure clear on what is what.


If the battery is charged, the bike will run for awhile without stator. Or volt reg. So if it isn't running, something else.

If charged not stator or volt reg.
You can trouble shoot starter, will probably lead you to cause. But it isn't starter problem. You push started and still ran bad. I am thinking loose connection somehere

 

That's what I was thinking about the charging system too. Battery has enough voltage I would assume it's good. I can find all the grounds from the diagram, but I'm not sure what you mean by the positive connections. Relay and fuses we're good btw. I cleaned the battery connections. No clue on how to find a loose connection. There's just so many places to check that would be a pain to get continuity from. How should I test the starter?

 

You need to charge the battery and have it load tested.

You gotta make sure the battery is in good working condition before you try to track down a problem in the electrical system.

Just because a battery shows proper voltage with a voltmeter does not mean it is good.

Load test...

 

That sounds very much like the problems I had on my 97 883 Sportster when the battery went bad and on my 2002 1200 Sportster when the battery post broke.

I would take a real close look at the battery connections, both ends, and the battery.

 

Thank you all! If I did all this work and it's the battery I'm not even gonna be mad. Just relieved haha. I'll let everyone know what I find when I get it load tested. I take it oreilley can do that?

 

What do you mean the battery post broke?

 

The positive cable should go to a terminal, one big wire to starter, and other the electrical system.

Did you put charge on over night and try immediately? Try 10 amps for 5 minutes and try with 10 amp on. See if new noises or try to start.

Not sure but I would have thoughgnhhat year would run with marginal battery after push starting. But I don't know.

Tighten battery. Then follow big wires to next spot and tighten. Follow back big wire from starter if easier.