Hi and thanks , I have a 2002 Fatboy FLSTFI and I can't get it to start. I just had the engine remanufactured by Harley, I removed and reinstalled the engine myself. New items that I installed on the engine was a new stator and rotor and a new MAP sensor. When I first tried to start it, it just made big clunck sound, I couldn't tell where it was coming from but it sounded like in the pirmary case. I took the battery out and put it back on the charger, and I removed the primary cover again. I waited a couple hours, the battery was at full charge, I put it back in and tried to start it. I left the primary cover off cause I wanted to see if the jackshaft was popping out, it was, it was making contact but just spinning like the clutch hadn't engaged. Then it would finally make a vain attempt at turning over.
So I took the battery out again and charged it. I took stator/regulator connection apart, the circuit breaker connection was dirty so I cleaned it, I also took the spark plugs out. I first turned the back wheel and checked that the primary gears all moved ok and they did. I put everything back together but left the spark plugs out. I then hit the start button and it surprised me because it actully turned over like it was supposed to and I felt the rush of air from the plug holes. So I put the plugs in and tried to start it but all I get is the engine turning but never firing. It has enough fuel, I can smell fuel if I try to start it too many times. I checked the battery load when starting, it drops from 12.6 to about 9.7-10.0 when i'm holding the button. The starter just makes the sound like its trying relly hard but nothing happens. Is this fuel related? This is a fuel injected bike. I'm not sure if the starter is the problem or ignition or what. Anyway thanks for any ideas, thoughts.
Mike
Their is a good chance that your battery has the 12 volts but not the amps. You really need to do a load teast on your battery. Also I take it the new motor is stock and has not had the ci steped up or u may need compr3ession release's installed...myself i do not think its your timeing. i really would do a load test on the battery its a good start.
Sorry to hear about your problems with your FatBoy.
After a good review of your problems, my suggestion would be to check your timing. Remove your plug, bring your piston to TDC and look at your rotor.
Next, after charging the battery, which by the way should not drop down to 9.7 volts while trying to start bike. Connect the cap end on the plug and ground the plug on the casing ( by hand ) With other hand, turn the engine over and see if you are getting spark to the plug.
I have an old Pan Head and you think you have problems ? Mine is 6 volt and try to get parts or repairs for one of those.
Anyway, just had to say that .! If you still have problems, start from the beginning with the old MAP sensor and go forward from their.
P.S. if you have good timing and a spark at the plug, its got to go the fuel.
P.S. May need to replace your battery ?
Really sounds like you have knowledge, have at it.
Hope this has shown some light on your repairs.
It sounds like an ignition timing issue, you need to reset the timing follow the repair manual's procedure, there is usually a mark on the backing plate of the stator that line s up with a notch on the case. Depending upon the direction of the fly wheel rotation the stator's back plate notch must be about 1/8" advanced in the opposite direction of the flywheel rotation, in other words in order to get the timing set from zero (which is when both the notch and the other corresponding notch or scribed line are lined up to one another perfectly) you must slightly move the stator plate toward the direction of rotation then lock down the stator plate hold down bolts. Be aware this is a generic description of the procedure. My observation in the past dealing with rebuilds is that the timing must be set to a static timing setting (which I just described) to get the bike to start initialy then fine tune the timing with a timing light, this is a procedure that should probably be done by a bike shop but you can do it yourself with the appropriate specs, tools, and maybe a repair manual and a little overall knowledge which it sounds like you possess.
Mike, From what you have narrated it seems that you have an electrical problem. It is not the battery alone. Take out the plug lead and see if it has spark (blue spark) when you crank the engine. Or remove the spark plug and crank the engine with the outer body of the plug touching the cylinder head (metal contact for the current to pass). If it has blue spark, then the electrical part is fine else it needs attention. The spark plug gap also may need adjustment. Do it if it is too much or too less. or try putting in a different plug if you one spare.
SOURCE: Is it possible to clean the fuel pump of my 2002 Fatboy FLSTFI?
Try running sea foam a couple of times.
SOURCE: location of the fuel filter
fuel filter is located in the fuel tank at the end of the fuel pump
SOURCE: how to replace front brake
Just take your old line off and replace it with the new line. Be careful because the brake fluid will damage your paint if it's DOT 4. One you have replaced the brake line, fill the master cylinder with the proper brake fluid. Open the bleeder valve and let gravity do it thing. Usually once the fluid starts to flow out of the bleeder valve, all the air is gone as well.
But if the brake lever still feels spongy or no brake at all, first bleed the master cylinder. Squeeze the hand lever and hold it while you loosen the union bolt on the end of the master cylinder. Once the pressure bleeds off, close the valve and repeat the process until you get no air bubbles. Then, move down to the brake caliper and do the same thing until you get no air and a full brake lever. You must do it in this order exactly. Squeeze the lever, open the valve, close the valve, let go of the lever. Do not allow the master cylinder to run dry during the bleeding process.
Good Luck
Steve
SOURCE: My 1999 Harley Davidson Fatboy
Dennis,
The battery seems to be low. Please have it recharged and try again.
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Thanks, I did check the spark, it looks fine
Well I would expect the manual to explain that but I can't find any mention of that,nor can I find it on the internet. Do you have any documentation that I could get to read abou it? Thanks
There is spark at the plugs, I can't find any info about a timing mark on the stator so I don't think that is a valid solution. I have removed the Starter, and did the tests as described in the manual that tests for open or closed connections on the different parts of the starter, all the tests were good so I have to assume the starter is good. How do I check that fuel is being injected? or is this problem something prior to fuel being added? Is it worth or are there places that I can have the starter tested?
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