I started having trouble with my 2002 Ultra classic fuel injected.
All of a sudden it started to run rough and have surging problems.
I have installed a thundermax about 3 yrs ago and have had no problems
First I cleaned the fuel filter and fuel pressure regulator.
Ran great for two wks, so I figured I was on to something.
Replaced the fuel filter didn't fix it. Replaced the fuel pressure regulator didn't fix it. Replaced the fuel pump, didn't fix it.
Got on to thunmdermax and notice the front AFR wasn't working so I replaced the front O2 sensor didn't fix it.
Out of nowhere it started to run good. Ran it for two days and about 10 miles from home it really started to act up. Running so rough, popping from throttle body and exhaust, died on my while riding and was able to get it back started without stopping. Roughest ride ever for me.
I also put in a new IAC motor.
I took thundermax off and put the HD module back on to see if I could read codes, but never could get it started. The bikes wants to start for about 10 seconds then dies. I thought I read in the codes that the crankcase position sensor was the code so I replace that.
Made it home. Haven't been able to get it started since.
Found out that the wire to the front fuel injector was broken. I also had followed many wires cut one open to look and put a electrical nut on it while I keep searching. Many attempts to fine the proper connector to the injector and trying to get it started I found the sk25 pigtail fits the injector perfect.
I reinstalled the map (thundermax) into the bike, but no luck.
I put old fuel pump back in, old IAC motor back in and tried the map again. No luck.
Now if I turn bike on and off a few times then try to start it, it seems to have the best chance at running for about 5 seconds and dies then turning it over again and again for several times before I can get that 5 seconds of running back.
Please feel free to ask questions, I'm really trying to figure this out here at the house.
I wonder if I did something else to bike on that 10 mile rough ride home, maybe it was only running on one cylinder most of the time. I just know it wants to start so badly that I'm hoping I'm not to far from getting ride again. I'm just stuck on that it wants to run then dies or quits like it runs out of gas after the fuel pump seems to pump up gas with the on off on off trick I started.
Thanks
Rick

 

Don't laugh. This may seem dumb. I had a strange rough riding engine on my '02 at the beginning of summer. It turned out to be a loose spark plug. Never know. Otherwise, I have no idea how to help.

 

Thanks, I have also replaced the spark plugs. I think, I don't know cause it won't start, but the bike will probably run smooth if I could keep it running for more then 5 seconds every 3 or 4 tries of turning it over. The roughness and surging was the bad wire to the fuel injector, I forgot I also replaced the fuel injectors. I get the AFR on the thundermax to work again so fixing the wire probably fixed the rough riding. I'm really lost right now. Thinking of taking off the thundrmax and putting the hd module back on and that may be my next step if I don't get some other direction from this site.
Thanks again
Rick

 

Make sure there are no pin holes in any of your in-tank fuel lines.

 

check the o-ring in the quick disconnect on the fuel line

 

Have you looked at the main ground coming from the battery and the hot wire to make sure they are making good connections ?

 

It is a new battery. The connection to the terminals are tight. Is that where you are talking about? The battery is getting a lot of use and gets low. I only have it on a battery tender, so after a while I have to stop and let it get back to being charged.

 

This is something you should check. If the bike runs fine when the tank is full, but acts up at say, 1/3 or 1/2 down, this could be the problem.

 

i like the quick disconnect,they can be very fussy to get seated right. must be absolutely clean.

 

I would check the voltage to the fuel pump and if it's good, have the fuel pressure checked professionally if you don't have the tools to do it yourself safely.

May need to scan the PCM data and see if fuel trim is correcting a lean condition, what the map/baro readings are, temps, etc. if the computer thinks your 10,000 feet above sea level it will lean down the fuel system.

All are possible factors.