My pump went **** up at about 120,000. Not too bad.

 

My '07 StreetBob was at about 24k (2009) but I wasn't able to figure out the problem and no one from any of 7 dealers I spoke with could give me any answers. It wasn't until a couple years, and probably close to 20k miles later, that I figured it out by accident while changing the fuel filter. The fuel injection on these bikes were new in '07 and I don't think many saw any problems at first, and I think that the Dyna line vibrates more than most others and thats why they're wearing out sooner.

 

I replaced the line 4 years ago, still running the original pump at 50,000+ miles . I removed the console and the panel on top of the tank. That way I could get my hand down into the tank and was able to replace the hose and clamps without removing the fuel pump from the tank. The whole job took me a little over two hours (that's with taking the tank off and working on it on the bench).

 

Could this be my problem (a leaking fuel line) if my bike will not start and ONLY starts if i shoot Throttle/Carb cleaner right into the intake (2003 EFI Softail).

 

You could have a hole in the in tank fuel line. But mine and others could still start their bikes. So my guess is NO that is probably not keeping your bike from starting. You need to do a little more trouble shooting. Is it throwing an error code with the check engine light staying on?

How many miles on the bike and have you ever cleaned your injectors or at least run some injector cleaner, like Techron fuel system cleaner, mixed with your gasoline? Have you ever cleaned your throttle body? Is your battery in good condition?

not to hijack this thread but I suggest you start your own thread on hard starting.

 

I never had a code when I had my issues, only a fail to start. I've got over 85,000 miles now. That's 60,000 miles on my less than $10 Auto Zone fuel line.

 

UPDATE:
Turns out, I had a damaged wiring harness.

Following the advice given in this thread, I did my dead level best to hear spraying inside the fuel tank indicating a pin hole in the fuel lines. But the spraying sound just wasn't there. Stopping just short of pulling the fuel pump and inspecting it, I decided to drain all of the gasoline, and put fresh gas in it. But after running through two tanks, the problem came back. I finally broke down and took it to the dealer.

The first thing the dealer did was to check the fuel pressure. And if they actually did what they described, they did their due diligence to verify fuel pressure. And it passed with flying colors.

The dealer then moved on to engine codes and found several historic codes pointing to a temp sensor, a TGS, and an ECM. But when it came to getting current codes, of course, they couldn't duplicate the problem.

Since I've put 3 TGS's in it over the last 3 years, I refused to believe it was a TGS. Finally, after almost a week at the dealer the bike threw a code. So they hooked up a diagnostic computer and found some serious voltage irregularities when they turned the handle bars full lock to the left.

Apparently when I changed the handle bars three years ago, I routed my brake line behind the wiring harness that comes from the under the tank on the right side and goes into the fairing. I should've routed the brake line in front of the harness allowing the harness to move freely. They found 6 wires in that harness in various states of damage.

In conclusion; all of the money I saved by changing my bars myself, I just spent having the dealer find my error. And if you add in the 3 TGS's I replaced, that cost goes up even more. Now, my bike runs, and is more responsive that it's been in quite some time. It was just pure coincidence that my idle problems would occur when the bike was at a half a tank or less.

I have to hand it to Jamie, the service manager, at Falcon's Fury Harley Davidson in Conyers, GA. He communicated with me throughout the entire process, and listened when I offered feedback.

 

Tagged

 

Anybody know the o-ring part number or size for the check valve that unscrews from the bottom of the tank?

 

http://partsfinder.onlinemicrofiche.....asp?make=hdmc




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