So tonight I am pulling out the fuel pump assembly and checking the lines and changing the fuel filter! Wish me luck

 

I had almost the exact same thing happen to my 05 a few months back. Me and 2 other mechanics went over it, and all the symptoms came back to either a) bad gas, or b) because of all the backfiring, timing. Turned out to be c) bad fuel pressure regulator. Never would have guessed low fuel pressure, but at least I know for the future. A friend of mine in the parts dept at the dealer told me this (and holes in the fuel line) are a common issues in the 02-05 bikes.

Good Luck

 

This happened to a buddys bike not too long ago. He had an after market ignition that went bad. The Indy said that ignition (dont remember the brand) was notorious for failing under heat. Just a thought

 

Well we took out the assembly in the tank and replaced the fuel filter and regulator and I still have the problem. We inspected all the line and cleaned the tank as the primer inside the tank was peeling.

Last night we were messing around with it more and I think I found the problem. I have an intake leak on the left side. We sprayed throttle body cleaner on the intake manifold going in to the heads and found that the bike reacts and bogs down when spraying meaning my gasket is shot. I am getting the gaskets today..... Lets keep the fingers crossed

 

Changed out the intake manifold gaskets last night and I still have a leak at the flanges on the left side of the bike. Is it common for the flanges or manifold to warp so that they wont seal? I am confused! As a temporary fix I am thinking about applying some hi-temp gasket sealer around the flange to see if it stops the leak until I can get the new flanges. Any opinions?

 

When you put the intake manifold on, make sure it is all lined up properly and the exhause mounting fasteners are all loose. Snug down the manifold bolts a little at a time and do them alternately so the whole gasket gets seated equally all the way around. Personally, I'd avoid the Hi-Temp gasket sealer. Next time you need to replace the gaskets you will have a beotch of a time getting that $hit outa there. JMHO.

 

I rode to Americade this past weekend and the bike ran like ****! Somtimes good and others really bad. Yesterday morning I jumped on the bike and it was sputtering, coughing and misfiring every time i rolled onto the throttle. It was very frustrating and embarrassing. At one point I just cracked the throttle and went through 3 gears it a matter of seconds and rev'd it up. After that the bike ran great for about 100 miles......? How does it go from one extreme to another. I am now thinking a dirty injector. Especially after finding the paint peeling in the tank. I think that when I rev'd it up it blew whatever was blocking the injector though.....

Any thoughts?