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Discussion in 'Motorcycle Tech Talk' started by Danny, Dec 10, 2017.

  1. Danny

    Danny Member

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    Attempted to start my 01 FLHTCI and upon hitting the start switch, everything went blank. No more dash lights, no nothing. Checked the battery and saw the positive terminal had melted plastic from a nearby wire jacket and the battery actually had a small hole near the terminal that was caused from the heat. Before hooking up the new battery and perhaps duplicating the same occurrence, I'm thinking about checking for a short at the solenoid or starter motor. Is this sound and if so how do I do that??
  2. Red Rider

    Red Rider Well-Known Member

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    Check for shorts nearest the burn area. Did it blow any fuses? If not, the short is most likely right near the battery. Sometimes wires get pinched under the seat. Make a thorough check around that area. Let us know what you find, please, so others may learn.

    Sorry for late response, didn't see it earlier. Anyone else want to weigh in?
  3. Danny

    Danny Member

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    Thanks for the reply. I did check all around the area and found nothing suspicious so I installed a new battery and it kicked right over with no issues. I'm now assuming that the battery was the issue or maybe the positive terminal was loose. The confusing thing is that I have a load check/battery tester and when I first attempted to test the battery, the analog needle bounced around a bit and showed the battery as weak, then rose abruptly to show 350 CCA's. I was going to change the battery anyway because of the small hole in the case. The battery was 2 months out of warranty :mad: and I always keep it on a battery tender.
    I have put on about 300 miles since changing the battery and so far, so good. I DO however, have another issue with idling and stalling. Feel like helping me out on that one too??
  4. Red Rider

    Red Rider Well-Known Member

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    Sounds like the battery itself shorted out - happens, and what you saw is a common symptom of that.

    As to your next problem, fire away, but if it is an EFI issue, I'm little help. Carb guy, and not even great with them. Other folks do read these (hopefully!).
  5. Danny

    Danny Member

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    Ok, here goes. The bike won't idle when starting cold unless I hold the throttle and make it idle at about 1100 rpm's. After a few minutes it will stay running and then I'm off and riding. Now lately, it will intermittently stall when I take off in 1st gear and just yesterday I was in 4th, coming down a hill, doing about 50 mph and it stalled and then restarted on its own.
    As a first resort and an easy one, I changed the engine temp sensor but that was before the aforementioned stalls so that had no effect. It's getting progressively worse also. The techs at Harley mentioned something about an o-ring kit for the fuel injector asbly. Whadda you think?
  6. hotroadking

    hotroadking Super Moderator Staff Member

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    EFI

    Could be any number of things, if its not setting any codes
    that makes it harder, what year bike.
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  7. Red Rider

    Red Rider Well-Known Member

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    Well, it sure sounds like an EFI issue, like HRK said. Does your 01 FLHTCI show any codes? Do you have the service manual, and know how to retrieve codes? I'm guessing you do, as you seem knowledgeable, but gotta ask.

    I know it ain't your pilot jet or pilot air screw adjust!
  8. Danny

    Danny Member

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    It's a "01" FLHTCI and I also have an intermittent issue with the speedo. I can however, get it to show me codes
  9. Danny

    Danny Member

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    No harm in asking. I only seem knowledgeable because I'm a refrigeration mechanic for 38 years but this is my first Harley. I will spend some time on the codes and see if that sheds some light.
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  10. hotroadking

    hotroadking Super Moderator Staff Member

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    Check your engine codes to see if there are any, normally you'll get a CE light that stays on, but after 50 start attempts it clears the light.

    Speedo issues on early 00's is attributed to a dirty or bad speedo pickup most of the time. That magnet is on the back right top of the trans and an allen will remove the bolt, pry it out and clean it, don't fubar the o-ring. If the problem persists then a new speedo sensor is needed, the connection for it is in front of the rear tire.

    Orings could be a culprit, so could a dirty fuel filter, it's in the tank, also you have two lines coming off the bottom of the fuel tank, one feed, one pressure return, inside the tank HD used a plastic hose to go from the pump to the line, it's known to get pin holes, after you get enough you can't get full pressure and you end up with drive ability problems.

    Ge the tank down to 1/4 full. Then turn on the ignition but don't start it, you should hear the FP energize, sometimes with holes in the right direction, on a 1/4 tank of gas you might hear fuel hitting the inside of the tank

    You could pull the dash and the inspection cover over the fuel pump and look in doing the same to see if the plastic line has holes. It's a common problem. Not saying thats it but it's possible.

    There are a ton of parts on an EFI system, and you can chase your butt off and spend a lot of money trying to find it, Might be best to have a pro tech check it out, having a bike that stalls at 50 isn't safe. $100 to a tech will be cheaper than $500 swapping parts.
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  11. Danny

    Danny Member

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    Thanks! Lots of info. I did check the codes and "d02set" came up. All others were do clr. I guess that is my speedo sensor. I cleared it and now all read do(1 thru 10)clr. I have not ridden the bike yet so I have no feedback on that.
    You mentioned o-rings. Would that be for the stalling/poor idle issue? If so which o-rings? I have already replaced my fuel filter but haven't checked the fuel pump hoses. The bike has 75,ooo miles on it and I have never inspected or cleaned the injectors. BTW, is that charcoal canister thing a joke? Should it be removed or replaced?
    I see your point about bringing it in. Guess I'm gonna have to break down (pardon the pun) and have someone troubleshoot it for me but I would like to eliminate as many questions before doing so.
  12. hotroadking

    hotroadking Super Moderator Staff Member

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    I was referencing the o-rings from your previous post for the injectors.

    It wouldn't hurt to replace them, however I doubt thats your problem.

    Fuels today are ultra clean, there is a filter in the tank, and perhaps it's
    in need of replacement, or the pin hole problem in the fuel tank internal line, bad plugs, bad sensor (there are several), etc etc

    BTW if the speedo keeps acting up then I'd bet your speedo sensor on the trans is
    going bad, I had to replace three on my 00 heritage, they were POS, eventually HD got the part straight, but for a while there they were a problem.

    Since you don't have the scan tools to check all the info in the system or watch it running the hundred bucks to get it tech'd out maybe cheaper than replacing parts one by one until you hit the problem.

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