02 roadking sputtering
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Stage III
Joined: Sep 2021
Posts: 3
Likes: 0
From: Illinois
02 roadking sputtering
Hey guys just joined. About a month ago i sold my 1200 sporty for a 02 fuel injected roadking. The bike sat for about a year with a 1/4 tank of gas. Everything ran fine until about the 2nd week, when I noticed a hesitation/sputtering only then i really pin the throttle. I put injector cleaner in but had no luck. Please help! Im an 18 year old college student and I dont have the money to get the bike completely inspected . Im assuming Im either having a fuel problem or maybe something with the air intake? Suggestions please. The sputtering seems to get worse when the bike is hot
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,071
Likes: 11,093
From: San Diego, CA
I would first buy, rent, borrow a fuel pressure gauge and check the fuel pressure at the fuel tank fitting. All the pumps, pick-ups, regulators are in the tank. The HD fuel pressure is around 55-62 psi. If you have good fuel pressure, that will rule out some of the usual problems with the EFI pump/regulator components.
Another thing to check for is debris in the fuel tank... Those year tanks had a fuel tank coating/lining that can fail. It then breaks off in pieces/chunks blocking the fuel flow to the pump... The pieces of lining float around and seem to first affect high rpm. Then as the chunks increase in size and/or quantity, it will gradually affect the lower rpms. When really bad, it can severely restrict the fuel flow.. If it's the lining, you have some work ahead of you. You'll need to clean out the tank. When my 2002 had the lining peel, I just cleaned out the tank and then left it bare... I just try to keep the tank full... haven't had an issue since..
If you suspect a leak at the throttle body/intake... you can get a propane torch (unlit of course) and direct the flow around the areas you suspect a leak and see if the engine changes (ie: increases or decreases rpms)...
Since it only seems to happen at full throttle, make sure your air cleaner filter is clean too....
If all that checks OK, you may need to have the fuel injectors themselves inspected...
Good luck with the repair... let us know what you find..
Another thing to check for is debris in the fuel tank... Those year tanks had a fuel tank coating/lining that can fail. It then breaks off in pieces/chunks blocking the fuel flow to the pump... The pieces of lining float around and seem to first affect high rpm. Then as the chunks increase in size and/or quantity, it will gradually affect the lower rpms. When really bad, it can severely restrict the fuel flow.. If it's the lining, you have some work ahead of you. You'll need to clean out the tank. When my 2002 had the lining peel, I just cleaned out the tank and then left it bare... I just try to keep the tank full... haven't had an issue since..
If you suspect a leak at the throttle body/intake... you can get a propane torch (unlit of course) and direct the flow around the areas you suspect a leak and see if the engine changes (ie: increases or decreases rpms)...
Since it only seems to happen at full throttle, make sure your air cleaner filter is clean too....
If all that checks OK, you may need to have the fuel injectors themselves inspected...
Good luck with the repair... let us know what you find..
Stellar HDF Member
Joined: Sep 2020
Posts: 2,419
Likes: 2,858
From: Southeast
Agree with everything Hattitude says.
I also had a sputterin' going on and did a thread about it here. It may not be the same as what you've got going on, but it may help you understand a little better what's going on inside that tank. Mine is an '06 Road King Classic (EFI).
https://www.hdforums.com/forum/ignit...d-misfire.html
I also had a sputterin' going on and did a thread about it here. It may not be the same as what you've got going on, but it may help you understand a little better what's going on inside that tank. Mine is an '06 Road King Classic (EFI).
https://www.hdforums.com/forum/ignit...d-misfire.html
Seasoned HDF Member
Joined: Nov 2018
Posts: 10,833
Likes: 6,485
From: Canada Flats
Everything above , also cleaning the iac would help as well , lots of videos on the subject , but most don't mention turning on the ignition and cyling the run / stop switch ( do not start ) , this will open / close the pintle and do a more thorough job of cleaning it . Place a rag inside the tb to catch all the debris , then use a tooth brush to clean the butterfly and seat .
How many miles on the bike ? If it's over 25k , your better off replacing the fuel filter , pressure regulator and hose , like Hat said , all inside the tank .
#12 is the iac on the tb , I use tb cleaner to clean my buddy's bike when he brings it to me for service , once a year .
https://partsfinder.onlinemicrofiche...UEL%20INJECTED
How many miles on the bike ? If it's over 25k , your better off replacing the fuel filter , pressure regulator and hose , like Hat said , all inside the tank .
#12 is the iac on the tb , I use tb cleaner to clean my buddy's bike when he brings it to me for service , once a year .
https://partsfinder.onlinemicrofiche...UEL%20INJECTED
6th Gear
Joined: Sep 2011
Posts: 10
Likes: 3
From: Colorado
I had a friend with a 2002 Road King that had a similar problem. Turned out to be the wiring to the injectors we’re not made long enough.
Try letting the bike idle or run at 2000 rpm and push on the injector wiring with a dowel and see if it starts to sputter.
Try letting the bike idle or run at 2000 rpm and push on the injector wiring with a dowel and see if it starts to sputter.
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