Howdy All, sorry for the lengthy post but trying to be as detailed as possible:

Earlier this year, I picked up a 2005 Dyna Superglide FXDI (Fuel Injected). It had around 7000 miles when I picked it up, and it just now tripped about 8800 miles. The only mods to the bike are a Dynojet PV-1 tuner running a "Stock Improved" tune from Dynojet, and a K&N Aircharger intake. Otherwise everything is stock, and as I'm aware - OEM.

Last week I was out riding, and made the assumption of filling up with bad gas - as the bike ran fine for about 75 miles through twistys and had a great ride - stopped for a drink for about an hour or so, and then the bike would fire fine, run for a minute or so and then die on me. To make a long story short, I treated the tank with HEET fuel treatment and put about 2 gallons of 91 octane fuel into the bike to dilute the tank, got the bike up to highway speeds and was able to make it home. The next day I took it out for a spin and no issues, so I figured the HEET took care of the poor fuel and I was back in the clear.

Today my father-in-law and I rode about 100 miles with no issues, and I thought it had to be bad fuel and the future was nothing but blue skies and open roads. Bike ran and idled fine all throughout Northeastern Oklahoma. We stopped for lunch for about an hour, and then the exact same thing happened. Bike would fire fine, run for a minute and then die on me.

There was a powersports store nearby, and I was able to get the bike there, and talk to the service manager. I showed him what was happening, and he mentioned it was potentially the fuel pump going bad or the tuner was on the fritz. We then restored the stock Harley OEM tune to the ECU (Stored in the PV-1), and the bike did the same thing. He recommended that I try to get it up to highway speeds, as the pump would still operate, and try to get it home/dealership and figure things out.

After painfully getting it from stop light to stop light - I was finally able to get it on the highway and up to 50-75mph and it ran fine once I didn't have to stop. Bike still had plenty of pep, and was able to ride it the 75 or so miles home to Tulsa.

Here's a link to a Youtube video of how the bike is acting, it idles fine to the 42 second mark, and then sputters and dies: - I pulled the backstrap off the tank and took a peek inside - it's very clean with no rust.

Has anyone experienced an issue like this, have any advice, or potential fixes? Really trying to not take it to the Harley Dealer and pay an arm and a leg when I have the hands, tools, and hopefully with your input the knowledge to fix this myself. I've worked on carburetors before but this is my first EFI bike.

Let me know what you think, or if I can provide any clarification!

 

A fuel pressure test would be a good start. I don't know if you've done these or not, but I would look at the fuel filter and possibly a hole in the internal fuel line. Dying at idle can mean a dirty IAC.
I know it seems like a fuel issue but a poor connection at the ground cable (and the battery terminals) will make a bike do strange things.

 

Thanks Nevil! I checked the battery which is good and strong as well as the terminal connections, and the ground cable which is secure. I don't have a fuel pressure gauge, and for the cost of the gauge I can just about buy a new fuel pump, regulator, filter, and new internal fuel lines...so I went with ordering all internal fuel tank parts from JP Cycle. As a side note, I stopped by O'riellys to see if I could borrow a fuel pressure gauge, and it was $120 to rent...not a deposit, to rent.

When I pulled the Fuel pump out of the tank, the fuel strainer or sock, whatever it's called was partially disintegrated, and there was no evidence of the pieces being in the tank. My guess is the fuel pump has sucked up about half of the sock which has gummed up the pump/regulator/fuel filter causing the drop in fuel pressure.

Anyway, I'll replace everything and see if that solves the issue!

 

 

try this don't work take it back https://www.harborfreight.com/fuel-i...ter-62623.html sounds like a fuel press. problem to me. You could pull the door off where the pump is and turn ign switch to on DON'T START just so the pump press. up and see if there are any bubbles from the lines inside tank, if so you found the problem . Does it do it with a full tank of gas or half full?

 

Well, after I picked up and replaced everything on the interior of the fuel tank...I'd be willing to bet my issue was a dirty fuel filter. Now, I don't have everything back together yet to be 100% sure this was the issue, but it sure looks like it.

That's what I get for waiting to disassemble the fuel delivery apparatus on the interior of the tank until I had all the parts to rebuild it!

 

That's nasty!

Make sure you clean the tank out before you put the new filter in.

 

Alright...so I replaced everything - Fuel Pump, Fuel Filter, Fuel Regulator, and all internal fuel lines. I received everything from JP Cycle, all spec'd to fit an '05 fuel injected Dyna Superglide.

When the pump primes, and when the bike is running, fuel is shooting out of a hole at the bottom hole of regulator. I know it's tough to see, but here's a video:


Here's an image of the hole on the bottom of the regulator housing:




I threw the bike back together, and rode it a bit. You can hear the fuel spraying inside the tank while riding. Any ideas on next steps?

 

Fuel pump primes for about 2 seconds from a timer in the relay before startup. Then it counts so many pluses from the crank position indicator and of course once running runs all the time while running. This maintains 65 lb pressure. All the rest is bled off by the check valve there. That way it idles or WOT, it has constant fuel. My thoughts are that dirty filter may not be the problem unless you are referring to it cutting off at idle.. Idle goes first with a true dirty filter. Cars are the same way. Some Toyota's do not even prime but have two relay system for protection. Your final protection is the Signal light/bank angle switch that kills pump if the bike goes over too far too long.
Your MAP sensor throttle bottle does not need that piggyback tuner to run properly to maintain the 14.7 -1 air-fuel ratio to run with full power and long engine life. Never add any more additives to the tank then amount of fuel. They will melt that fuel sock off. A tuner making more then 14.7-1 just does like the old carbs did and washes the oil from the cylinders.