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EFI Sportster Motorcycle Talk (2007 and up) For 2007 and above Sportsters

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  #201  
Old 27th January 2015
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wkong wkong is offline
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Bumping it back up! Horrible corrosion all over the fuse block. Blasted it with some cleaner, loaded up new fuses and relays with grease, and boom. No more issues starting. It seemed that most people's system relay was going first, but my fuel pump relay went first. It would crank and crank and crank and never get enough fuel sometimes, and then out of nowhere viola, starts right up. Wondering if the previous owner was having problems and couldn't figure out why, which might explain why an otherwise pristine bike with under 10k miles was going for so cheap.

Just to help those using the search function... bike will crank but won't start.
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  #202  
Old 27th January 2015
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Every 2007-2009 model should have fuse blocks and relays examined regularly.
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  #203  
Old 28th January 2015
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Quote:
Originally Posted by wkong View Post
It seemed that most people's system relay was going first, but my fuel pump relay went first. It would crank and crank and crank and never get enough fuel sometimes, and then out of nowhere viola, starts right up.
The system relay controls the fuel pump.

There are two identical relays:

1. Main/system that controls the fuel and ignition systems.
2. Starter relay that controls cranking.

So what happened is the system relay finally closed.
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  #204  
Old 1st June 2015
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rockmanbm rockmanbm is offline
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I believe mine is doing this now as well. I will be stripping and cleaning the fuses and relays tonight. Glad this forum is here to give appropriate info
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  #205  
Old 2nd June 2015
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Quote:
Originally Posted by Bone View Post
No but it took 4 years for the untreated relays to fail on Jenn's bike, as did it on Nytstr's bike. So it is quite logical/likely that it would take at least that time before it might occur again, probably longer with the grease.

Obviously YMMV and others might vary because of differences in usage.
Thought I'd report back, here we are another 4-5 years later and I was just in there finally replacing the stock battery.

While there I spot checked the relays and there's little or no new corrosion. The replacement relays still look fine.
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  #206  
Old 2nd June 2015
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That is good to hear. I will be tearing into mine and cleaning the entire fuse box, replacing fuses and relays on my 2009. Looking back on it, mine has been having problems over the last 2 weeks with intermittent starting issues, and the IAC started cycling while off. Anyone been able to source some good relays that are sealed?
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  #207  
Old 12th June 2015
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I was able to clean corrosion off and the bike worked flawlessly. I wonder of a '10 fusebox is sealed better and will fit on a 09
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  #208  
Old 12th June 2015
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Quote:
Originally Posted by rockmanbm View Post
I was able to clean corrosion off and the bike worked flawlessly. I wonder of a '10 fusebox is sealed better and will fit on a 09
Different animals

Fuses 2007-2009
Spare
Instruments o
Ignition g
Battery bn/gy
Lights be
Accessories o/w
P&A ignition fuse
Spare
ECM be/gy
Fuel pump o/gy
System relay
Start Relay
Spare

Fuses 2010-2013
Ignition g
Battery bn/gy
Lights be
Accessories o/w
ECM be/gy
System relay
Start Relay
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  #209  
Old 12th June 2015
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Quote:
Originally Posted by rockmanbm View Post
I was able to clean corrosion off and the bike worked flawlessly. I wonder of a '10 fusebox is sealed better and will fit on a 09
Yes, 10 is sealed better, cause it's a complete redesign.

No, not compatible.
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  #210  
Old 1st January 2016
Ultrarunner Ultrarunner is offline
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I have an 09 883c, and have finally resolved this issue. Without going into the entire back story, I purchased this bike in August, and have put 6000 miles on it since. It was garage kept and immaculate (until I got my hands on it....), with 5000 miles on it, and I doubt had ever seen water.

I started having battery drain issues about a month ago, and replaced the battery, as I figured it was original. Put an HD battery in it, which was fine for a couple of weeks, when I started chasing potential issues. Turns out the new battery had a bad cell. So, HD gave me another, which was dead the following morning.

I had already seen and read this thread, and had cleaned my fuse panel as well as testing my relays. The fuse panel had very, very little corrosion on it. The relays tested fine (with multimeter, not just a click test). Charging system checked out fine, I had already gone through wiring off battery with a fine toothed comb, and was getting frustrated.

I put in new relays, just in case.... that was 4 days ago, and it solved the problem. Even though the old ones tested fine, there was one that must have been working improperly intermittently. Argh. Very aggravating. So, I will be cleaning the fuze panel with every oil change as well as keeping a couple of spare relays in my tool kit. Pretty cheap insurance.

Of course, while working on this my FZ 1 fuze block arrived, so I'll be installing that soon. Glad I figured out the charging issue first! Thanks to the forum- this is a great resource.
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