BigJ, Since you are doing all that work anyway I'd replace fuel lines too they can start to come apart inside like the tech suggested, if you have a little of the hose come off after the filter it could start plugging up circuits that could cause problems.

 

Its 10 yrs old,,, Have U even done the reg maintenance on it.
like plugs, wires, air filter, fuel filter,?? they don't last for ever.

in 4yrs ours has had miss issues 3 times in 34k...

1st time. - battery cable bolts loose. easy fix just tighten them. (just started doing it out of the blue)

2nd. - bad gas. (started short time after filling up) added gas dryer and ran it through.

3rd time was just 2 weeks ago on a 5 day road trip and 500miles from home, cause was a pin hole in the fuel line inside the tank.
Took 4 tanks of gas to figure it out.. the bike would run fine for 100 to 115 miles, then she'd start missing out and coughing . fill up again and she'd run fine again for 100 or so miles.
1 thing I did notice was she'd turn over 3-4 times before she'd start up where she usually fires right up. That was because the fuel line pressure couldn't build up.

They replaced both hoses, diaphragm, fuel filter, and all orings inside the tank. Total part where around $145, with two hrs labor two get her running.

"Charles" in Huntington W. Virginia is where the work was done and the Tech Derrick did a supper job. Plus they took me right in and fixed the problem.
It was great that they got me back on the road that fast so the two other guys I was with could get back to our riding Vacation.

The wrench Derrick said the pinhole could and usually just gets bigger if not fixed and could leave U totally stranded.

Unlike some of U guys that HATE the dealers, I Like them. If it wasn't for the Charles HD who Had those parts in stock, I'd could have been stranded 500 miles from home.

I do some work on our bike (like changing the oils, adjust the clutch, greasing, adding mods) but somethings for me its better to let the ones who works on the bikes everyday do it.
I also use a local INDY for tires and brakes. He is a lot closer than any of the 5 dealers around and Saves us $$$.

So IMO there is a time when we need for them.

Check Ur battery cables.
Plugs wires and plugs if there old
As said above, remove the V&H FP and see if that helps.
After that could be Ign Switch, a short in the wiring somewhere.
Did U recently did a new mod and then it started?
Or even ever done a mod that the wiring could be suspect.
Start/Kill switch.

and if U havent change the hoses and filter inside the tank it'd be good preventative maintenance anyway.
Derrick the wrench who fixed mine said he is seeing the problem this yr more than ever... His thoughts is the Ethanol in the gas is the reason the hose are going bad.

 

Agree on your point about Dealers ......As to OP i know they can be expensive but so is my bike and to be honest i couldn't be asked all what your doin ..... i would just take it in give em the keys and let em sort it and if it isn't then they take it back and work on it it until it is and i wouldn't pay the second time around it's their problem not mine that way i know i can go ride and not think about it again

 

I think the cumulative here might be closer to a single issue. Hose in fuel line in tank could cause the issue and be more prominent when after 100 miles or so in each tank. Clogged fuel filter or sediment in the tank could cause random issues but not likely only during release of the throttle. Electronics certainly can cause it but more likely adding a PC now will hide issues not fix them.

As for the dealer haters, I am one. Only because most of the dealers here hire short term wrenches and if the book doesn't tell them what the problem is, they can't fix it. I'm not paying for them to throw parts at the bike at my expense while they "learn" what the issue is. A good seasoned mechanic no matter where he works is worth his weight in gold. I will pay for them to diagnose and fix my scoot when I can't, no matter where they work, indy or stealer. I also hate the fact that a wrench in a dealership doesn't or can't make what a good indy can.

 

You could also have plugged injectors. The holes in them are not very big, and when you let off the throttle there might not be enough pressure to get the fuel through.

 

fcsallan...

I agree that most shops have some newbie Wrenchs, with the turn around they have they almost have to. Having a newbie isn't all bad, but they have to have someone in the shop that's good enough that can help and teach the new one's the ropes when there in over their head.

I will say the the dealer I visit for repair if I need them has a PHD wrench thats worked at the same dealer in Indianapolis for 27 yrs, If my bike goes in to them, HE alone is the only wrench that I'll let touch my bike.

U can demand a certain wrench to be the one who works on U bike, not sure soon know that....

As far at the Indy here in our town that I let work on my bike, He also is a HD school grad back in 54. HE worked for our local HD dealer that went out of Business back in 74.
He then moved to Cali and worked of one of the HD dealers out there for another 9yrs or so then moved back here and started his own shop, working on Harleys only..
Along with his brother in law, his other wrench there, both of them together have over 80 yrs of working on harleys experience. I trust them two completely.

 

Well guys, for now, I am going to order a new high flow fuel filter and replace the internal fuel lines. Im going to get a new air filter and install a fuelpak. Ill let you guys know how it works out. Thanks for all your input!!!!

 

I'm in agreement with the ethanol comment. My 2001 Ultra Classic recently developed a huge fuel leak. I turned on the ignition, it pressured up the fuel system, and I started smelling gasoline. I looked at my left leg and saw fuel SPRAYING out the underside of the tank. BOTH fittings were leaking fuel profusely.

I took it to a little shop down the road. I trust this guy more then the HD dealership. The guy told me that all SIX of the O-rings on both the feed and return fittings were almost completely dissolved. He said he's getting two or three older bikes in his shop per month with similar problems. Apparently, the ethanol, even in premium fuel, attacks the O-rings and other rubber/synthetic fuel system components.

I know what you're thinking: "The bike is 10 years old. It's not unusual for these O-rings to fail."

I would agree with this if both fittings didn't fail at the same time, and ALL six of the O-rings weren't toast.

 

Big J,

You have one of the problems that is Frustrating, Time Consuming, and perhaps Costly to troubleshoot.

V@H Fuel Packs do indeed work well for Stage 1 bikes. Your bike must however be in good working order or the FP could compound the problem.

I agree with everyone that the tank internals would be the first place to investigate but don't overlook your electronics such as the Crank Position Sensor. Keep us posted. I'm especially interested.

 

I'm still thinking intake leak or bad gas???

Josh... Did you get it back from Cycle City already? Is it fixed?