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2003 Road King fuel pump problem

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Old Jun 9, 2022 | 10:12 AM
  #11  
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If the main circuit breaker is kicking out you'll lose power to everything.
After a little research I see your bike has a 3rd relay controlling the fuel pump. Where it is on your bike I don't know.
. Here's a link to online wiring diagram.

https://serviceinfo.harley-davidson....b75f1d5b!!0!92

keep on it, you'll get her going.

 
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Old Jun 9, 2022 | 10:22 AM
  #12  
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Originally Posted by s-glide76
If the main circuit breaker is kicking out you'll lose power to everything.
After a little research I see your bike has a 3rd relay controlling the fuel pump. Where it is on your bike I don't know.
. Here's a link to online wiring diagram.
https://serviceinfo.harley-davidson....b75f1d5b!!0!92
keep on it, you'll get her going.
I remember having issue on my 03 Road King, and keeping a spare relay in the pouch. They are all the same part number.
 
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Old Jun 9, 2022 | 11:41 AM
  #13  
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S-glide, you're a champ! That wiring diagram is just what I needed! Thanks, man! The fuel pump relay is on the right side of the bike under the side cover, along with some fuses. Two other relays and more fuses are on the left side. All relays and fuses have checked out as good, working condition. I replaced the relays with now ones anyway, to be sure. They're cheap and generic.
And God bless you for the encouragement, too. Yes sir, I'll keep at it til I find the gremlin. Then I'll be a good boy and post the solution for everyone's benefit.
 
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Old Jun 15, 2022 | 12:46 PM
  #14  
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I had a 2003 Road King with very similar issues as what youre describing. I checked the fuel line in the tank and it did have a hole in it so i replaced it but the problem continued.

Turned out to be the Variable Speed Sensor in the tranny was bad. Pull your VSS and clean it off, it will likely have a build up of fuzzy looking metal shavings on it.

Sometimes you can get away with just cleaning it, but sometimes you need to replace it if its too far gone.
 
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Old Jun 16, 2022 | 03:45 PM
  #15  
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Update: THANKS!!! Especially to BigMike and S-Glide.
The information you have given me is INVALUABLE!
I have experience in mechanics, both automotive and motorcycle, as well as other applications. I have electrical and electronics experience as well, and I am definitely able to make use of the information and teaching you great men have provided.
The problem I'm experiencing with my '03 Road King running fine, then the fuel pump failing to come on, causing a NO START condition, after a short ride, HAS NOT BEEN DUPLICATED LATELY. I've been riding her around the neighborhood, longer and longer rides, almost every day, and returning to my garage, shutting her off, and she's been good, re-starting every time. The fuel pump issue has not happened again.
So, gentlemen, I'll have to wait until the problem recurs in order to use all the info I learned here, to run down the specific problem, which I can now do, thanks to YOU!
I want to thank you very much, for all the thought, experience, and time you've put into helping me.
I want to assure you that as soon as I find the Road King fuel pump not working again, I'm going to do put all the advice and directions to work, AND GET BACK ON HARLEY-DAVIDSON FORUMS ASAP to let you know the results.
God bless you!
 
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Old Apr 21, 2023 | 11:24 AM
  #16  
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What was the end game? My 07 Sportster is doing the same thing. Sometimes it even cuts off while running, and won't restart fir awhile. I changed the relay and replaced the fuel pump, but the pump continues to stop working occasionally.
 
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Old Apr 21, 2023 | 11:57 AM
  #17  
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Originally Posted by korey
What was the end game? My 07 Sportster is doing the same thing. Sometimes it even cuts off while running, and won't restart fir awhile. I changed the relay and replaced the fuel pump, but the pump continues to stop working occasionally.
Did you check for holes in the fuel line inside the tank? With the bike running, take the gas cap off and listen inside the tank. You'll hear it if theres a leak.
 
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Old Apr 21, 2023 | 12:28 PM
  #18  
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I chose to replace everything in tank. Solved. Hose, pump, filter. But did not do anything with bung.

If going to open up, replace all you can.

In these threads, I realize old. Best to note exact problems. Sometimes details are lost in story.
Lights on, no fuel pump on start up.
Stalls half tankAll electric goneWon't start hotJust cranks
 
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Old Apr 22, 2023 | 12:58 PM
  #19  
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I experienced the exact same problem you explained. First I changed the system relay and it started, so I went for a ride. After several miles the bike quit and when I cycled the ignition switch no fuel pump. So I replaced the pump and went for a ride. After a few miles I made a pit stop and was happy the bike restarted only to quit 5 minutes later and no fuel pump. Obviously not a bubbling hose if the pump won't run.
 
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Old May 7, 2025 | 01:53 AM
  #20  
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Default Same problem ongoing with fuel pump relay!

TheNeonGuy here. Same problem still happening. I own EIGHT motorcycles. So I've just been riding them instead, including my 2002 Electra-Glide.
The problem is the same one I and others have been trying to solve for about three years!
She's a 2003 Road King with a stock Twin Cam 88 motor.
After a ride, I shut off the bike and the motor won't re-start. It happens whenever it wants to. Short ride, long ride, short interval after riding or overnight. No pattern to it. Happens in any weather, Summer or Fall or Winter. It happened two days ago. Waited 8 hours and then she started!
There is no voltage from the relay to the fuel pump. The motor will run on starting fluid. There is spark. After waiting usually 8 hours, sometimes for days, the bike will start and she runs great. Buy it's a crap shoot whether she'll start again after going somewhere.
I've read about several other guys having the SAME PROBLEM, on this Forum and on others, since I originally posted about it, a couple YEARS ago or so.
It's frustrating to see the SAME ISSUE plaguing other Harley owners, with nobody having a clue and no answers.
Don't tell me about a weak battery, bad wiring connections, holes in the fuel lines, bad relays or circuit breakers, bad battery ground connection, blah blah blah.
Been there, DONE THAT! All that and more have been checked, over and over again. All those things check out FINE!
This Road King is a garage queen, never been outdoors overnight! No rust anywhere, no corrosion, never even been in the rain, not even taken to a car wash!
The problem seems to be that there is no voltage to the relay that sends volts to the fuel pump because apparently the ECM is not sending the voltage or not grounding the circuit which allows volts to flow to the fuel pump, whatever the case.
I need REAL HELP here, and the damned stealership won't even talk to me. Dallas Harley-Davidson does NOT work on older bikes no matter how much money I offer them!
I'll NEVER buy a motorcycle from that place.
Anyway, please see if you gentlemen can advise me what to do/check/replace next.
This Road King is beautiful. She's the 100 Year Anniversary Model with Mustang seat, Vance & Hines pipes, black & silver paint, 1000 watt, four speaker stereo, silver pinstripes, and a newer, matching Harley trunk. She looks fantastic and rides GREAT.
I want to keep her and ride her til I drop dead.
I'd hate to sell her with this problem.
Maybe the ECU is bad? Maybe the crank position sensor is intermittent? Might be the variable speed sensor? I understand the CPS sends a signal to the ECU to let it know the engine is running, which triggers the ECU to activate the plunger in the relay, closing the circuit inside, sending voltage to the fuel pump.
Again, there's no voltage TO that side of the relay, no volts from the ECU. I've paid three Harley mechanics over the last two years, hauled the bike to two shops, and NO ONE can fix it! Unbelievable!
Am I on the right track here with maybe checking the wiring from the ECU to the relay? Is there ANOTHER relay between the two? Maybe a bad ignition or kill switch? But how does she run on starting fluid?
What's the next step to correct it? I'm freaking out.
PLEASE ADVISE: what's the procedure to display a trouble code? I did it a long time ago but there was no code at that time. Can't remember how to do it now. It isn't easy like on layer models.
THANKS to all you guys, my Harley-Davidson-loving friends, here on Harley-Davidson Forums!
God bless you and ride SAFE!
 
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