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Old 11-02-2012, 08:29 PM   #1
speedracertdi OP
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Harley wont run.

2003 Fuel injected Fatboy, TC88 balanced motor. It just started missing one day, two days later, it will barely run. Ive changed the fuel filter, fuel pump, fuel regulator, all the in tank fuel lines, throttle position sensor, crank position sensor, cleaned air filter, cleaned throttle body, new plugs, and still no love. Even removed and checked all electrical connections and ignition coil. Took it to an independent shop they had no luck either. They think the computer might have gone bad and i have corrupt maps. I havent looked at the injectors and think they may be sticking in either an open or closed state a little too long during pulse signals. Is that possible? The new plugs are soot black and the end of the exhaust is too (rich condition). Its going to the dealer tomorrow unless someone has any ideas.

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Old 11-02-2012, 08:52 PM   #2
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I dunno, it evidently is not a frequent problem, tell us about the dealer's diagnosis and ensuing repairs. Hope it ends up being an easy fix.
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Old 11-02-2012, 09:27 PM   #3
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Corrupt maps? Does that mean you have a Power Commander? If so remove it and see how/if the bike runs.
Is it showing any codes?
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Old 11-03-2012, 09:53 AM   #4
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Cam chain jumped a tooth or two due to a bad tensioner?
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Old 11-03-2012, 10:40 AM   #5
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so, is there a nice fat spark?
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Old 11-03-2012, 11:17 AM   #6
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I just fixed a problem on my EFI Husky, which like your HD, vibrates alot. The vibrations had worn a spot on a very critical wire, a wire that connects to the Fuel Pump, the Fuel Pump relay. the Fuel Injector and the Coil. The bike was cutting out, missing, backfiring, sometimes dying, all very sporadic and non-sensical, didn't really follow a pattern, because when the wire shorted out, it changed the vibrations and the wire would change positions. Be sure and check stuff like this before you start looking at corrupt maps etc.



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Old 11-03-2012, 03:22 PM   #7
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No power commander. I dont believe the independent shop's corrupt map guess.

Cam chains and tensioners were updated under warranty a few years back. Dont think thats it. It starts and idles fine.

Checked lots of wires and connectors. No chaffing or corrosion found.

Im stumped. Dropped it off at the dealer. Turns out the service writer is the son of one of my high school teachers (since deceased). And his family and mine live in the same small town in Georgia. The bike has been to this shop before for work when it was still under warranty and im still in their system along with the bike's service records. So with all that, i think he's going to make sure im treated right.

Will update what they find out.
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Old 11-03-2012, 03:32 PM   #8
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Dealer should be able to plug it into the H-D diagnostic systems and that may point to an obvious fault (failed sensor etc).

BUT computer diagnostics are not everything - we had a H-D in the shop a day or two back - poor running, no power, not idling unless the throttle was held open.

Computer said everything was fine

Problem traced to a loose clip on a fuel line in the tank - leading to low fuel pressure, lack of fuel in the injectors and the poor running problems.

Best of luck - sounds like you have the right relationship with the dealer to get it sorted.
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Old 11-03-2012, 03:44 PM   #9
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I think so too. Fuel pressure is 65 psi. Right where it should be. I should know something in a few days.
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Old 11-03-2012, 03:54 PM   #10
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Had an 05 Heritage ,prob was that the com.mod.was full of water ,not covered by insurance,needed new modular n maped. The dang thing is behind rear fender down low on the Soft Tails
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Old 11-03-2012, 05:59 PM   #11
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Quote:
Originally Posted by speedracertdi View Post
I think so too. Fuel pressure is 65 psi. Right where it should be. I should know something in a few days.
65 sounds high, most info I find shows a higher number than the standard of 45, but not as high as 65:

Fuel Pressure Regulator - Alsolocated in the fuel tank, the regulator controls fuel pressure between 55 and 62 PSI by returning excess fuel from the fuel pump back to the fuel tank. The return is also located in the tank, hence only one line (supply) coming out of the tank.
http://www.harley-performance.com/ha...injection.html
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Old 11-03-2012, 06:46 PM   #12
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Has new fuel regulator along with new everything in the in-tank fuel pump system.
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Old 11-04-2012, 05:05 AM   #13
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Quote:
Originally Posted by speedracertdi View Post
Has new fuel regulator along with new everything in the in-tank fuel pump system.
doesn't mean the new part is good.

I see a big list of parts thrown at it. What kind of diagnostics have you done, and what data did you gather?
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Old 11-04-2012, 06:02 AM   #14
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Yeah new doesn't always equal good. 65 PSI is at the high end of the range and can cause a rich condition. Throwing money at it rarely fixes it cheap if at all.
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Old 11-04-2012, 06:30 AM   #15
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Prior diagnostics prompted the replacement of the crank sensor. Its at Harley now so i should know something more tomorrow. Up till now, its been cheaper to throw parts at it, my friend works at another harley shop and is able to get me parts at 10% over cost. That roughly equals half off of retail.
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