I just got bike back from the dealer a couple of weeks ago after bike dropped to one cylinder. Was a rear female connector in the injection harness. This has been a continued problem as it happened twice last year. Well, lo and behold, I was out riding the other day and my bike cut in and out several times, wanting to sputter and die. Once after 5 miles down the road. I rode it another hour and fine. Rode 40 miles. Got gas and sputtering/surging again (more sputtering). Lasted 30 seconds. Started fine, but sputter upon take off. Got it going. About halfway home (20 miles) sputtered again. Did this twice. Bike seemed like it has a slight whine (doesn't sound like engine to me, but I'm no mechanic).

A few things: Bike had a total rebuild last spring. Went from 95" to 107" all bore. TTS. 50mm SE TB.

After leaving the dyno last year on way home:

1) April 2014: connector into injection harness broken on rear, run on one cylinder. Replaced.
2) June 2014: Rear injector bad (were brand new). Replaced.
3) Sept 2014: Stator and starter out. Also, throwing codes, wire that regulated idle in harness worn (noticed slight lope/varying idle). Replaced.
4) April 2015: 3rd ride of the year, dropped to one cylinder. Rear. Wire in injector harness. Replace.
5) April 2015: few days after bike back: Sputtering. Cutting in and out. No engine light/codes yesterday. Also, seems to have the slight varying idle.

Also, since last year, the bike seems to start a bit slow (figured it was starter, which part of it was. Replaced on the road with same stock HD starter) but sincle last year, slight smell of gas when it's a bit hesitant to start (not a huge delay, but subtle and noticeable to me since i noticed it last year.)

A few things were suggested last week, prior to bike getting fixed: Lengthen harness as apparently 03's were prone to this issue being crimped. I will do this today or tomorrow. Will check if any wires are broken. Some reading on this issue indicates might be further up in harness covered by insulation.

Like I said, I'm no mechanic, but figured I'd check and clean air filter and inspect wires. What else? From reading, clean IAC? What do I use. How?

Sorry for lengthy post and my mechanical stupidity, but my local HD mechanic (who I have always had faith in but seems less interested in my bike now that it has 100K and rebuilt) said: "that's what starts to happen on old bikes" when I asked what could be causing continued wire breaking in the harness and "we replace those all the time." Gee, thanks.

 

I think that with the age on your bike, that the wiring harness could be the source of trouble.

1 thing- soldered joints do not hold up on a motorcycle ( that is why cars and bikes use crimped terminals).
the vibrations will break the wire strands right where the tinning ends, by the wire insulation.

If you have done any solder fixes, look at those first.

with a wiring diagram- a tech with electrical knowldge and a meter can trace through and look for trouble spots.

this does not have to be a harley mechanic...any kid from a tech school could do this...got any Nephews or friend's kids who would want to make a $100 over week end?

They would look for resistance in the wiring and voltage drop through the circuits

thats what i would do.

Mike

 

Thanks Mike. Thankfully, my good friend is an electrical engineer.......I think I'll ask him!

 

good advice mk....you might also want to check the ground(s). Pull them off, clean everything an re tighten.

 

I'll be interested in where this goes... Not looking to hijack the thread, it's just I have the same issue on my '03 Road King.

Sputtering, sometimes when hot, other times cold, during accel and decal.... at high and low speeds...

Replaced plugs... good for a short ride then back to trouble...

Sprayed carb cleaner into the Idle Air Control sensor... good for a short ride then sputtering again.

Replaced fuel filter, ... good for awhile, rode great for about 10 miles then happened again after it had sat at work all night.

- I only have V&H slip ons and a K&N filter to effect air flow, which for the first couple years I had the bike didn't cause issue.

Driving me crazy,.