Thanks for your reply, Andy,

After I sold the Iron, the new owner didn't like the amount of noise that the Python slip-on mufflers were producing, they are very loud. I had a brand new pair of black mufflers stashed away which I intended using for MOT inspections, so I gave him those for free.

I removed the XiED's in the hope that it was those which were causing the rough running of the motor, but after they were removed the rough running persisted.

The sensors were removed six years ago when I had the header pipes powder coated, I tightened the sensors upon reinstallment.

I will try the suggestions that you have made, thanks.

I sold the Iron for less than it is worth at Ł3k, the new owner realises that and he isn't too bothered about the teething problems so far, he knows it is a sound low mileage one previous owner machine. The other problem was with perrished seals in the fuel valve, they possibly dried out when the bike was being stored for eighteen months.

 

If it really is running lean on the front cylinder then on conclusion the fuel doesn't match the air.

A leak somewhere or the injector isn't working as it should? Check for leaks around the muffler and the balance pipe. Squirting brake cleaner or similar around the intake side or swapping the injectors round might also be something to try.

 

The owner said that one of the injectors popped out of it's housing and he put it back in, could it be that he didnt reinstall it correctly or possibly damaged a seal?

 

I know nothing about them to know what "popped out of its housing" actually would mean for correct operation. It cannot be good. Maybe a new one is required?

Did the whole thing come out of the inlet manifold? Could the thread be damaged as well as the seal?

 

Hello again, Andy,

It was # 12 in the diagram which popped out of it's seating in the intake manifold, I'm assuming that it is the front injector, these aren't threads, they are a push fit.

 

That would seem to be the place to concentrate on.

 

From a 2008 manual. Based on what your friend has said it looks like it would be a good idea to buy new o-rings for the injectors.

REMOVAL
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK.
To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding.
2. Unplug Maxi-Fuse. See 7.34 MAXI-FUSE.
3. Models with side-mounted horn: See Figure 4-50. Remove screws (3), washers (2) and cylinder head bracket (1) from engine. Unplug harness connectors [122] from horn (4).
4. Models with 4.5 gallon (17.0 liter) fuel tank: Access to the fuel injectors and fuel rail may be easier if the fuel tank is raised up as follows:
a. Remove seat.
b. Loosen (but do not remove) front fuel tank mounting screw. Remove rear fuel tank mounting screw, washers and nut. See 4.4 FUEL TANK.
c. Place a clean shop cloth between front of fuel tank
and front fork upper bracket to protect fuel tank finish.
Carefully pivot rear of fuel tank upward and prop in position with a block of soft wood or other suitable device.
5. See Figure 4-52. Unplug engine sub-harness connectors from fuel injector connectors [84A], [85A] (7, 8).
6. Remove screw (5) and retaining bracket (2). See Figure 4-52. If neither fuel supply hose (1) nor fuel rail (6) are to be replaced, it is not necessary to separate them. Skip the next step.
7. Disassemble fuel supply hose (1) from fuel rail (6) as follows:
a. Hold fuel rail in place and with a gentle twisting motion, pull fuel supply hose straight up out of fuel rail.
b. Remove o-ring (4) and sealing washer (3) from fuel supply hose. Discard o-ring and sealing washer.
8. Hold fuel injectors (9, 10) in place by pressing down on harness connectors (7, 8) and with a gentle rocking motion, pull fuel rail off injectors.
9. With a gentle twisting motion, pull fuel injectors out of intake manifold.
10. Remove and discard o-rings (11) from both ends of each fuel injector.

INSTALLATION
1. See Figure 4-52. Apply a thin coat of clean engine oil to new fuel injector o-rings (11). Install an o-ring on each end of fuel injectors (9, 10).
2. Push fuel injectors into intake manifold with harness connectors (7, 8) facing up. Rotate fuel injectors so that harness connectors are outboard of injectors, as shown in the figure.
3. Gently press fuel rail onto free end of fuel injectors. Press fuel rail down until hole in fuel rail molded-in bracket lines up with mounting hole in intake manifold (12).
NOTE
An alternate method of assembly is to first install rear fuel injector in the intake manifold and front fuel injector in the fuel rail. Then install the assembly onto the intake manifold.
4. If the fuel supply hose and fuel rail were separated in the disassembly procedure, reassemble as follows:
a. Slide new sealing washer (3) onto fuel supply hose fitting until washer contacts the collar. Slide new oring (4) onto fuel supply hose fitting until it contacts the washer. Lightly coat o-ring with clean engine oil.
b. Push fuel supply hose into fuel rail bore until collar on hose is flush with top of fuel rail.
NOTE
The fuel supply hose must be oriented properly when installing the retaining bracket. See Figure 4-53. 5. See Figure 4-52. Install retaining bracket (2) and fastener (5) as follows:
a. See Figure 4-53. Orient fuel supply hose so that locating flange (2) is positioned as shown in the figure.
b. Install retaining bracket (3) so that U-shaped opening in bracket fits around fuel supply hose and locating flange as shown in the figure.
c. See Figure 4-52. Secure retaining bracket (2) with screw (5). Tighten to 60 in-lbs (6.8 Nm).

 

We gave the Iron 883 a good going over, checking for air leaks, tightening everything.

We removed the Chinese air filter and reinstalled a stock filter from a "Forty-Eight".

The Iron is now running as it should without any hesitating, or engine racing, she is now idling at a constant 1000 RPM.

A job well done and my buddy is chuffed with his Iron 883.

Thank you for your help, Andy.

 

Nice one. Glad you got it sorted.

 

Thanks, Andy,

I'll be turning my attention to my XR1200 tomorrow.

I will be puting my own stamp on it as a "Flat Track Racer".

All the carbon fibre bodywork has reduced it's weight somewhat, I wish I could do the same with my body.

Since I retired ten years ago, I have put on 14 Kg in weight.