Harley wont run.

Discussion in 'Road Warriors' started by speedracertdi, Nov 2, 2012.

  1. speedracertdi

    speedracertdi Been here awhile

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    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.

    :ear
    #1
  2. willis 2000

    willis 2000 neo-quixote

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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.
    #2
  3. anotherguy

    anotherguy Long timer

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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?
    #3
  4. ausfahrt

    ausfahrt mach schnell

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    Cam chain jumped a tooth or two due to a bad tensioner?
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  5. anonny

    anonny What could go wrong?

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    so, is there a nice fat spark?
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  6. AustinJake

    AustinJake TE450-KLE-FXDWG

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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.

    [​IMG]

    [​IMG]
    #6
  7. speedracertdi

    speedracertdi Been here awhile

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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.
    #7
  8. pebble35

    pebble35 Long timer

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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 :ear

    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.
    #8
  9. speedracertdi

    speedracertdi Been here awhile

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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.
    #9
  10. Piute N Judose

    Piute N Judose RIDE TO LIVE

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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
    #10
  11. AustinJake

    AustinJake TE450-KLE-FXDWG

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    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/harley-fuel-injection.html
    #11
  12. speedracertdi

    speedracertdi Been here awhile

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    Has new fuel regulator along with new everything in the in-tank fuel pump system.
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  13. kraven

    kraven Hegelian Scum

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    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?
    #13
  14. anotherguy

    anotherguy Long timer

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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.
    #14
  15. speedracertdi

    speedracertdi Been here awhile

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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.
    #15
  16. Mattbastard

    Mattbastard Lazy ass

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    It's been my previous experience on other bikes that when there's an instantaneous problem on a bike it's ignition related rather than fuel related.

    But, that was on carbed bikes.

    On another note, what is the deal with some mechanics? They just throw parts at the problem and don't actually troubleshoot anymore! If I was working on your bike I'd hook up a wideband o2 sensor to see what's happening to the AFR during these problems. If there was no change I'd hunt down an ignition problem. If it gradually went lean or rich, fuel.

    Is life really that hard for some people? This is common sense. :becca
    #16
  17. kraven

    kraven Hegelian Scum

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    Only after you do it wrong and then have someone who knows how to diagnose show you how to do it right. Some people don't have mentors for their mechanical endeavors and just learn to throw parts at it from reading the intertubes, alas.
    #17
  18. anotherguy

    anotherguy Long timer

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    Apparently the diagnostician is wrong now isn't he? Until now it's been cheaper? Really? Is it fixed? No. Cheap parts that don't fix it are simply money tossed into the wind. Are you using Autolite plugs by any chance?
    #18
  19. AustinJake

    AustinJake TE450-KLE-FXDWG

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    That's how I understand it as well, the injector stays OPEN for a specific duration based on what RPM, what throttle opening, etc, and the higher fuel pressure will be delivering more fuel than what is really intended.
    #19
  20. Smopho

    Smopho Been here awhile

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    I'd be looking at a crankshaft position sensor. Easy and cheap to replace.
    #20