I have an '06 Sportster service manual....If would work for '02, you're welcome to it, just pay shipping?

 

Silverfox, have you found the problem with this yet? I have my bike back in the shop for this same problem I have been dealing with, they can't find any problem, of course they are not looking where I have troubleshot and told them to look at. Just curious if you solved your problem?

 

I have an 04 1200R with the same problem. Has anyone found a solution yet?

 

This is why I scrapped that **** and went to circuit breakers and bare-bones wiring with a turn-key switch.

Check the following:

-Starter relay (again).
-Ignition switch (check the wires...they won't always short, could just be a burnt/bad/pinched one in there that just BARELY works and gets all fussy when it's vibrated around for a bit).
-Test the start/run wiring from your switch packs...especially if the bars are internally wired. This one I know from experience. Regardless, check them anyways.
-CLEAN (yes, again) your knockdown sensor and starter relay (replace that ****er if you're in ANY kind of doubt...it WILL work if one part of it goes bad, trust me), along with everything else...I recommend Corrosion X...that stuff is AMAZING.
-Check ALL of your grounds (again).
-Check your breakers for your main power connections. Your problem actually sounds like they may be popping and resetting, which would explain the time delay before it kicks back over, as well. Those aren't fuses if they have the threaded poles on them, they're breakers.

If it's still failing at that point...take the bike apart, find the gremlin that's hiding in it, and kill him.

 

You don't have a short.That would blow a fuse.You have an open connection somewhere.Power feed to the fuse box loose,loose ground or a broken wire inside the insulation where you can't see it.A bare power wire will short to ground and blow a fuse.It you have a bare ground wire it will still do what it was intended for.I would start the bike and idle it.Then slowly move wires back and forth and tap on things to try and duplicate the problem.That will help pin point the area for further inspection.

 

All it takes is the factory bob and it will wear out the ignition over time. A few weeks ago I met a guy with a 2007 C model that was having this problem and he showed me how things could shut down just by wiggling the key in the ignition. He didn't turn it off he just wiggled the key and the lights and speedo display went blank....

 

Check your ground wire where it attaches to the engine case.

 

Good point if your grounding strap is good underneath the Bike would seem to me either the Ignition Module or Main Circuit Breaker is defective if lose everything ....

 

Check your 90* connections on the coil. Pull them, and give them a good squeeze either with your hand or pliers, and then put it back on.....A loose connection there would also cause you to lose all power. I had it happen. Running down the road and the engine cut out/speedo turned off/etc, and then a few seconds/minutes later it would fire right back up. As stated earlier, start the bike up and start figgeting with wires, and you'll find it.

 

Mine had the same problem, but it tripped the circuit breaker on mine. Ended up being the stainless steel oil lines I put on that were shorting out on the starter.