2003 FLH engine surge/sputter
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Joined: Oct 2007
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From: Lubbock, Tx
2003 FLH engine surge/sputter
My 2003 FLHTPI has a sputter going on in the engine. It usually occurs after the engine has warmed up and at highway speeds. It almost feels like it is running out of fuel. I can twist the throttle and the bike accellerates ok but once back to cruising it starts up again.About a year ago the dealer replaced the fuel filter and checked fuel psi(it had an idle issue).
I had changed the spark plugs and plug wires but no change. To me, it kinda feels like the throttle position sensor might have a bad spot in it because it seems to only happen in a certain area on the throttle. Just kinda guessing, I was hoping someone with some experience would be able to point me the right direction. Thanks
I had changed the spark plugs and plug wires but no change. To me, it kinda feels like the throttle position sensor might have a bad spot in it because it seems to only happen in a certain area on the throttle. Just kinda guessing, I was hoping someone with some experience would be able to point me the right direction. Thanks
Road Warrior
Joined: Oct 2014
Posts: 1,764
Likes: 266
From: Roma Alberta
2003 had an issue with the injector wires breaking inside the insulated sheath from the wire harness along the frame under the tank, the injector wires are pulled tight and breaking inside. mine has the same symtoms and is throwing a code P0261-front injector open/low
Stage I
Joined: Jan 2014
Posts: 1
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From: Barstow, Ca
That sounds almost identical to my problem. I have a 2013 SG that at idle would jump from 900rpm to 1100 back down to about 1000 rpm at random. At cruising speeds only, it would sputter but not enough to kick off the cruise control. I had all the sensors on the engine replaced to include the ECU and it still does it. a mechanic said the front cylinder was running lean and hot. so now the only thing left to replace is the wiring harness, which cost $10 billion from the dealer. I don't wannna go that route but its leaning that way. don't know what else it could be if that don't fix it, nothing else left to replace.... any thoughts on this one would be greatly appreciated!!!
Last edited by PJEWELLY2K; Feb 6, 2017 at 07:19 PM. Reason: none
Road Captain
Joined: Jun 2013
Posts: 671
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From: Ontario, Canada
My 03 did exactly the same thing. It would run great but at a steady cruise is would seem to cut out for a split second. Almost like a hiccup. It finally started misfiring and set P0261. The wires going to the front injector had broken inside the insulation. It just looked like a slight narrowing of the insulation. I was able to wiggle the wire and get it to act up. I put a pigtail from NAPA on it and left the wire a bit longer so it wasn't getting stretched.
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Joined: Oct 2007
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From: Lubbock, Tx
Update:
I decided to replace the throttle position sensor since the issue occurred in a certain position on the throttle when the engine was at operating temp. Since replacing the throttle position sensor the issue has not happened again. I took the bike on fairly long rides over the last 2 weekends and it ran like a champ. Thanks for the replies.
Road Warrior
Joined: Oct 2014
Posts: 1,764
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From: Roma Alberta
a follow up to my previous post, the P0261 front injector open/low code I was getting from the intermittent miss at steady throttle positions on my 2002 FLHTCUI Ultra Classic turned out to be exactly the issue LazySundays posted that happened to his '03. I had read of a service bulletin issued in regards to the '03 FLHT models about the harness being pulled tight in this location. no bulletin was issued for the 2002 models.
I found the wire broken inside the insulator sheath about an inch above the connector that plugs into the front fuel injector. the wire was visually narrower and plastic sheath discolored from stretching, and bent easily in the spot where it was broken. cutting open the sheath revealed the broken wire ends blackened from arcing together.
the pigtail connector is an AC Delco part no. PT133, or GM part no. 1208-5491 for under $20.
I found the wire broken inside the insulator sheath about an inch above the connector that plugs into the front fuel injector. the wire was visually narrower and plastic sheath discolored from stretching, and bent easily in the spot where it was broken. cutting open the sheath revealed the broken wire ends blackened from arcing together.
the pigtail connector is an AC Delco part no. PT133, or GM part no. 1208-5491 for under $20.
Seasoned HDF Member
Joined: Apr 2012
Posts: 9,984
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From: Michigan
FWIW- My neighbor has an '02 RKC and he had a broken injector wire.
It was an intermittent miss.
The tech that diagnosed and repaired it said that it appeared to have been caused by a tie strap that had the wire too tight.
It was an intermittent miss.
The tech that diagnosed and repaired it said that it appeared to have been caused by a tie strap that had the wire too tight.
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Road Warrior
Joined: Oct 2014
Posts: 1,764
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From: Roma Alberta
I had read about this injector wire issue on the internet and made the mistake of mentioning it to them on the last trip, as soon as you say anything about the internet then they beak off about getting the internet to fix it. had to find it on my own FFS
Last edited by teeroy_; May 1, 2017 at 10:03 AM.
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