2005 Custom XL 1200 issues
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Stage II
Joined: Apr 2011
Posts: 2
Likes: 0
From: Marietta
2005 Custom XL 1200 issues
Hi guys, my name is Jeff, I bought this harley brand new in 2005, right now I have exactly 2000 miles on the odometer, it has never run right, and currently it will idle for maybe 3-5 minutes before it will stall, and it will also stall on me at lights and stop signs
The dealer told me last time i was there it was the stop **** and they replaced it last may, and I am still having the stall issue.
I've only ridden it 250 miles and im at my wits end with this bike, any suggestions on what I can do?
I've been riding since I was 6 years old (50+ years), and I've never had a bike that would not idle on its own. I appreciate any help you guys can give me!
The dealer told me last time i was there it was the stop **** and they replaced it last may, and I am still having the stall issue.
I've only ridden it 250 miles and im at my wits end with this bike, any suggestions on what I can do?
I've been riding since I was 6 years old (50+ years), and I've never had a bike that would not idle on its own. I appreciate any help you guys can give me!
Club Member
Joined: Feb 2007
Posts: 16,320
Likes: 306
From: Boynton Beach, FloriDuh
With no more technical info than that, it could be any number of things.
6 year old bike and 2,000 miles? 333 miles / year? You've definitely got a garage queen.
I'd probably start with a carb overhaul, as it's likely gummed up by now. Who knows what kind of cobwebs are in that thing.
It doesn't sound like you are much of a wrench, so why not take it to a good mechanic? If the bike is running that bad consistently, it should be that hard for the dealer or a good indy to troubleshoot it.
6 year old bike and 2,000 miles? 333 miles / year? You've definitely got a garage queen.
I'd probably start with a carb overhaul, as it's likely gummed up by now. Who knows what kind of cobwebs are in that thing.
It doesn't sound like you are much of a wrench, so why not take it to a good mechanic? If the bike is running that bad consistently, it should be that hard for the dealer or a good indy to troubleshoot it.
Thread Starter
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Stage II
Joined: Apr 2011
Posts: 2
Likes: 0
From: Marietta
I guess that you meant it should not be hard for a dealership to diagnose. I thought that I mentioned I had taken the bike to Earlsmall's Marietta shop no less than 3 times. To no avail. I then took it to Earlsmall's Cartersville and it still stalls. I am at a loss. I do know a fair amount about engines and that when you take it in to have a problem fixed that it should be fixed. Just shy of 500.00, two Harley dealerships, and less than 2000 miles later still stalls. I need help figuring out is it the Harley, the dealership, or is it a lemon.
Club Member
Joined: Apr 2011
Posts: 5,817
Likes: 7,850
From: SE Louisiana
Do you mean it idles for 3-5 minutes on a cold start up, and then stalls everytime you try to idle on a warm engine?
If so, it's a rich condition, you probably don't have to use the enrichment much on cold starts either because its to rich at idle.
If so, it's a rich condition, you probably don't have to use the enrichment much on cold starts either because its to rich at idle.
Stage I
Joined: Jan 2022
Posts: 1
Likes: 0
From: Central illinois
Hi guys, my name is Jeff, I bought this harley brand new in 2005, right now I have exactly 2000 miles on the odometer, it has never run right, and currently it will idle for maybe 3-5 minutes before it will stall, and it will also stall on me at lights and stop signs
The dealer told me last time i was there it was the stop **** and they replaced it last may, and I am still having the stall issue.
I've only ridden it 250 miles and im at my wits end with this bike, any suggestions on what I can do?
I've been riding since I was 6 years old (50+ years), and I've never had a bike that would not idle on its own. I appreciate any help you guys can give me!
The dealer told me last time i was there it was the stop **** and they replaced it last may, and I am still having the stall issue.
I've only ridden it 250 miles and im at my wits end with this bike, any suggestions on what I can do?
I've been riding since I was 6 years old (50+ years), and I've never had a bike that would not idle on its own. I appreciate any help you guys can give me!
To me it sounds like either your carbs or fuel pump is gummed up or your bike is running too rich/lean and needs a carb sync.
I am curious did you fix the problem and if so how did you fix it? I hope you didn't say screw fixing it and run it off a bridge as I have contemplated multiple times with my previous motorcycles/vehicles haha.
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Road Captain
Joined: Mar 2009
Posts: 654
Likes: 734
Hello Jeff I am an amateur mechanic I know this is years old and I'm not sure you'll even reply to me also I am sure you sold the bike but I love learning and am currently looking at a 05 sportster (I like to research problems beforehand so I can haggle a better price 😉
To me it sounds like either your carbs or fuel pump is gummed up or your bike is running too rich/lean and needs a carb sync.
I am curious did you fix the problem and if so how did you fix it? I hope you didn't say screw fixing it and run it off a bridge as I have contemplated multiple times with my previous motorcycles/vehicles haha.
To me it sounds like either your carbs or fuel pump is gummed up or your bike is running too rich/lean and needs a carb sync.
I am curious did you fix the problem and if so how did you fix it? I hope you didn't say screw fixing it and run it off a bridge as I have contemplated multiple times with my previous motorcycles/vehicles haha.
In terms of what was probably going on, well, they idle pretty lean from the factory, resulting in carb farts that often kill the motor, especially when they happen at idle. The tweaks that need to be made to cure this on the stock CV40 carb are well known. A little bigger pilot jet, say a 45 instead of the stock 42, and three turns out on the idle mixture screw, generally clears up the kinds of issues he was describing.
The idle mixture screw is hidden under an aluminum plug, because the government doesn't want you messing with it. A 1/8' drill bit, being careful to pull back as soon as it punches through the plug, followed by a sheet metal screw and a tug with a pair of pliers, gives quick and easy access to the screw. Three turns out from lightly seated cures a lot of the carb's problems. For race use only, of course.
Now of course, it's possible something else was going on, I have no way of knowing for sure. But that's the common cause of what he was describing.
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Stage II
Joined: Jan 2022
Posts: 2
Likes: 0
From: Central illinois
I can assure you that it wasn't the fuel pump. Unless he was idling in a weightless environment. The fuel pump on a 2005 model is better known as "gravity". Likewise it probably wasn't a carb sync issue, considering the bike only has one carb.
In terms of what was probably going on, well, they idle pretty lean from the factory, resulting in carb farts that often kill the motor, especially when they happen at idle. The tweaks that need to be made to cure this on the stock CV40 carb are well known. A little bigger pilot jet, say a 45 instead of the stock 42, and three turns out on the idle mixture screw, generally clears up the kinds of issues he was describing.
The idle mixture screw is hidden under an aluminum plug, because the government doesn't want you messing with it. A 1/8' drill bit, being careful to pull back as soon as it punches through the plug, followed by a sheet metal screw and a tug with a pair of pliers, gives quick and easy access to the screw. Three turns out from lightly seated cures a lot of the carb's problems. For race use only, of course.
Now of course, it's possible something else was going on, I have no way of knowing for sure. But that's the common cause of what he was describing.
In terms of what was probably going on, well, they idle pretty lean from the factory, resulting in carb farts that often kill the motor, especially when they happen at idle. The tweaks that need to be made to cure this on the stock CV40 carb are well known. A little bigger pilot jet, say a 45 instead of the stock 42, and three turns out on the idle mixture screw, generally clears up the kinds of issues he was describing.
The idle mixture screw is hidden under an aluminum plug, because the government doesn't want you messing with it. A 1/8' drill bit, being careful to pull back as soon as it punches through the plug, followed by a sheet metal screw and a tug with a pair of pliers, gives quick and easy access to the screw. Three turns out from lightly seated cures a lot of the carb's problems. For race use only, of course.
Now of course, it's possible something else was going on, I have no way of knowing for sure. But that's the common cause of what he was describing.
Ah okay I've only owned FI bikes and I am only used to working on them no idea about single carbs, since you seem more knowledgeable than me I'm currently having a problem on my 06 r1 if I am below like 4k rpms just cruising it will pop (not decel popping as it does it under light acceleration) and it will very lightly surge (almost can't feel it but it is still there) I've syncd the TB's changed the plugs cleaned the k&n replaced the fuel line with an "aftermarket" homemade one all the lines to the air box are on and tight.
Tbh I think I over oiled my air filter or maybe one of the connections in the wiring harness for my ignition coils is about to break(noob story time: when I changed my plugs I didn't turn one of my ignition coils closer to the engine and the rad fan was rubbing against it) , I would take it to a shop for a dyno run but they charge way too much (it's the only dyno tuner within 500 miles from me)
Bikes bone stock aside from the k&n filter
Anyway the bike rides fine and I dont feel the surge or get the acceleration popping on the highway it's just annoying being in stop and go traffic I just got it a couple months ago so maybe I just need to get used to it still.
Stellar HDF Member
Joined: Feb 2013
Posts: 3,072
Likes: 1,727
From: Dallas, Texas
Sportbikeguy - FYI . . . with your admitted lack of knowledge on Harleys, don't jump right in with a repair comment you know nothing about, makes ya sound arrogant AND dumb. Now for you R1 problem. Clean the K&N filter and LIGHTLY oil it. I assume you used a MANOMETER to sync the TB's. ( I prefer the old style 4 tube units over the vacuum meter units.) The thing is, once ya change the "Factory Set Up" such as changing to a less restrictive K&N, you upset the working perimeters on the system. Double check your F- up on the coil pack wires and consider a Tuner, cause yer running lean. Yeah, I have also worked on Non Harley bikes.