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techtalk:evo:trouble02 [2019/08/05 19:11] – [Typical Failures from Sitting Too Long (months-years)] ixl2relaxtechtalk:evo:trouble02 [2024/12/01 19:15] (current) – ixl2relax
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 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]] [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== EVO: Specific Troubleshooting ====== ====== EVO: Specific Troubleshooting ======
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 ====== Common Failures - Be Aware ====== ====== Common Failures - Be Aware ======
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 Over the course of many years, the following problems have been shown as 'common' for various reasons.((List prompted by 'lostNdallas' http://xlforum.net/forums/showthread.php?t=2074270)) Over the course of many years, the following problems have been shown as 'common' for various reasons.((List prompted by 'lostNdallas' http://xlforum.net/forums/showthread.php?t=2074270))
  
 +\\
 +
 +**Noises** \\
 +A common occurrence with Sportsters is all the noise they make. Especially for new owners, it's difficult to nail down if the noises are a sign of problems or if they are just normal. A list of noises that you may hear has been compiled to help with diagnosis or some just to ease your mind. \\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:ref:genmsr05|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
 +\\
  
 **Clutch Spring Plate Failure**\\ **Clutch Spring Plate Failure**\\
 The Spring Plate has caused untold headaches for many riders. When the rivets fail they get caught in between the friction & steel plates, causing the clutch to malfunction, damaging the plates & the clutch basket. __This problem is best addressed before it happens.__ The XLForum did an ad hoc poll of those who have or have not had failures of their Spring Plate. The poll showed the rubbermount models (2004-later) failing at double the rate of the frame mount models (1986-2003). The reason for the failures is unknown (??? due to a change in design and/or material, from rider increased horsepower or from the way the rider uses the clutch. ???).\\ The Spring Plate has caused untold headaches for many riders. When the rivets fail they get caught in between the friction & steel plates, causing the clutch to malfunction, damaging the plates & the clutch basket. __This problem is best addressed before it happens.__ The XLForum did an ad hoc poll of those who have or have not had failures of their Spring Plate. The poll showed the rubbermount models (2004-later) failing at double the rate of the frame mount models (1986-2003). The reason for the failures is unknown (??? due to a change in design and/or material, from rider increased horsepower or from the way the rider uses the clutch. ???).\\
 {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:priclutch01#spring_plate_failure|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}} {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:priclutch01#spring_plate_failure|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
 +\\
 +
 +**The Dreaded Clutch Basket Wobble (L84-90 models)**. \\
 +This is a known issue beginning either from a worn out basket or trap door bearing or possibly a worn inner basket spline or maybe a combination of them: \\
 +The late 84-90 sportster has the stator mounted behind the clutch shell, the problem is the stator needs a tight 0.060 clearance to operate right. \\
 +A clutch shell wobbles even when the bearing in the trap door is good, but once it gets worn, it's enough for the magnets to start contacting the stator. Then it's catastrophic for the charging system. \\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:ref:priclutch01#the_dreaded_clutch_basket_wobble_l84-90_models|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
 +\\
 +
 +**04-05 Oil Cap popping up**. \\
 +If you've noticed your oil cap mysteriously popping up, it could be a broken internal sleeve. One of the first symptoms is that the cap will not stay flush, but will protrude maybe an eighth of an inch above the tank surface. Eventually it will not click down in place at all. There is a fix for this instead of buying a new one. \\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:oil04g#style_oil_cap_repair|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
  
 \\ \\
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 Whenever you have electrical issues, the first thing to do is check the battery cables and do the basic four voltage tests. Then check the various ground points & straps. A huge number of issues are caused by battery cable deterioration and/or loose connectors. The negative cable to the frame is especially critical. All Sportster models occasionally have trouble with the battery cables but it seems to be even more prevalent on the rubber-mounted engine models from 2004-up (since the motor moves more in relation to the frame).\\ Whenever you have electrical issues, the first thing to do is check the battery cables and do the basic four voltage tests. Then check the various ground points & straps. A huge number of issues are caused by battery cable deterioration and/or loose connectors. The negative cable to the frame is especially critical. All Sportster models occasionally have trouble with the battery cables but it seems to be even more prevalent on the rubber-mounted engine models from 2004-up (since the motor moves more in relation to the frame).\\
 {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:elec01#battery_cables_-_the_place_to_start|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}} {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:elec01#battery_cables_-_the_place_to_start|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
 +\\
 +
 +**Starter Clicks**\\
 +Usually, this has one of four causes, in order of frequency: Battery Cables Loose, Battery, Starter Relay or Solenoid Contacts.\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:elec01#battery_cables_-_the_place_to_start|Battery Cables & Battery Testing in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:ref:elec03|Battery Options in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:elec02#relays|Relays in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:engctl02|Starter & Solenoid in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
  
 \\ \\
  
 **1998-2003 Nosecone Ignition Failure**\\ **1998-2003 Nosecone Ignition Failure**\\
-The 1998-2003 Non-Sport model used an integrated ICM on the Sensor Plate. These OEM modules had a high failure rate. The MoCo stopped providing replacement units as soon as they were allowed. The only choice for replacement is aftermarket versions (such as the Ultima version).\\+The 1998-2003 Non-Sport model used an integrated ICM on the Sensor Plate which was still located in the 'nosecone' behind the round cover. These OEM modules had a high failure rate, apparently due to the high heat in their mounting location. The MoCo stopped providing replacement units as soon as they were allowed. The only current choice for replacement is aftermarket versions (such as the Ultima brand).\\
 {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:ref:engctl01#ultima_-_nosecone_ignition|Ultima Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}} {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:ref:engctl01#ultima_-_nosecone_ignition|Ultima Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
  
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 {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:oil03#oil_pump_upgrade_26204-91a|Oil Pump described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}} {{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:oil03#oil_pump_upgrade_26204-91a|Oil Pump described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
  
 +\\
 +
 +**Clutch Slipping - Upgrade Pressure Plate**\\
 +Once you have upgraded to 90hp or more, it is very likely that you are going to notice clutch slippage under extreme acceleration. It is important to upgrade your clutch friction & steel plates & include a higher rated pressure plate. You also want to have an upgraded Release Bearing.\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:priclutch01#stock_diaphragm_springs_clutch_plates|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
 +
 +\\
 +
 +**Clutch Release Bearing Upgrade**
 +You might consider replacing the stock bearing, P/N 8885, which is a standard ball type bearing (equiv. to 6200). Using an angular contact bearing, which provides additional support in the axial direction, is a better alternative for this application. The upgraded replacement would be 7200B (not supplied by HD) and is an angular contact bearing.\\
 +{{:common:arrowright-200x20px-dkblue.jpg?50|}}  [[techtalk:evo:priclutch01#upgrade_clutch_release_bearing_-_hd_p_n_8885_to_7200b_angular_ball_bearing|Described in the Sportsterpedia HERE]]  {{:common:arrowleft-200x20px-dkblue.jpg?50|}}
  
  
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 **Fuel Tank/Pump Issues** **Fuel Tank/Pump Issues**
  
-**Oil & Hoses Issues**+**Oil & Hoses Issues** \\ 
 +\\
  
  

Trace: • EVO: Engine Control