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

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View Poll Results: Has your fuel pump failed?
Yes. It did. 87 14.26%
No. It hasn't. 523 85.74%
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  #21  
Old 14th June 2007
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jchick jchick is offline
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Sportster/Buell Model: XL50
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Quote:
Originally Posted by HellRazur View Post
The second choise shouldnt be No it hasent... it should be " Not Yet! "
Ditto. Mine hasn't failed *yet*, but something ain't right with the EFI system on my bike. (See herky-jerky XL50). I'd rather have carb farts, at least that can be fixed.

JC
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  #22  
Old 18th June 2007
MWD MWD is offline
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Here's a possible cause for the "fuel pump problem." Loosen your front tank bolt, and remove the rear one. Lift the back of the tank a couple of inches and set it down on a piece of 2x4:



You don't have to disconnect anything if you're careful and if you lift the rear of the tank only a couple of inches.

Now reach up into the center of the tank and pull down the fuel-pump wire. It may be taped to the tank as part of the assembly process. My wire looked like this, having been totally mashed between the tank and the frame rail.



Note the severe pinch in it from one edge of a backbone saddle trough. This is not just a cosmetic thing going on here -- we are talking about big-time pressure on a near knife-edge. I think this is the spot that may be wearing through with time and vibration.

Now drop the tank back into place and route the wire elsewhere. I winged it thus:



I'll probably tie-wrap it into place tomorrow before I hop on.

I believe the assemblers need this wire to be manufactured about six inches longer so they can put a proper loop in it, the way the service manual recommends, to keep it away from sharp edges.

I am not saying this *is* the cause of all these failures, but having a cable nearly knife-edged up against a hard surface can't be helping matters, and may be responsible for at least some of the recent non-starts.

p.s. I hope the images come through on this post. They aren't showing up in the preview, nor is the code. If I don't see them when this goes up, I'll post another reply with links to flickr.

Last edited by MWD; 18th June 2007 at 00:30.. Reason: repaired poor grammar
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  #23  
Old 18th June 2007
MWD MWD is offline
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Here are the pics:

Tank rear on block
Big pic of above

Pinched wire
Big pic of above

Wire relocated
Big pic of above

Any advice on how better to re-route this wire?

Last edited by MWD; 18th June 2007 at 00:40.. Reason: added links to larger pics
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  #24  
Old 18th June 2007
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nightsterman nightsterman is offline
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Thumbs up Thanks for the photos!

Thanks, I'm going to check mine out in the AM.

Peace,
Mark
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  #25  
Old 19th June 2007
btkicker btkicker is offline
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Great work MWD!

I checked my '07 Roadster (same small tank, efi, and all) and it's wires are where your new re-routed wires are!

Why the hell did HD move the wires only on the Nightster? I smell a recall to re-route the Nightster fuel-pump wires back to the normal spot.

again, good investigating.
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  #26  
Old 19th June 2007
btkicker btkicker is offline
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'07 Roadster fuel-pump wires:
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  #27  
Old 19th June 2007
MWD MWD is offline
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Thanks for that pic, BT. However, I may have confused some people. That pic of the crushed harness was taken *after* I pulled it out of the upper trough in the backbone saddle (where yours probably is right now). The crushed part was buried up between the tank and the trough. I pulled it down out of the trough and ran it straight back, avoiding either trough. In the "relocated" pic, the crushed area is invisible because it is now directly behind the tank's quick-connect.

I'm going to take a guess here: the tanks are delivered to final assembly with the harnesses taped to the bottom of the tanks, to save stress on the wires right where they enter the tanks while the tanks are being handled. If so, it's possible that the guy building my bike forgot to yank the harness free of the tape so he could loop/route it properly, and when he dropped the tank into place the harness got crushed. I don't know -- I'm just thinking out loud. If I try hard enough I can imagine ten different possible causes for what I saw on my bike. Perhaps my experience was one in a million rather than indicative of a trend.
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  #28  
Old 20th June 2007
Thumper74 Thumper74 is offline
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When I was buying my 07 Custom, I had picked out a Pearl white w/o security system. They got it down stairs from the third floor, we did the paperwork, put the tags on it and they fueled it up. Bike wouldn't start. The fuel pump was bad with .2 miles on the odometer. The F&I manager came out and put me on the two tone custom that I had been eyeballing for the same price as the white bike. So far I'm happy and Helen (the sales lady) made sure to put a Freedom bell on the bike for me
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  #29  
Old 20th June 2007
soto1994 soto1994 is offline
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Default Fuel Pump Failed

I have a 2007 Sportster Custom with the failed fuel pump at 225 mile. Tomorrow will be a week since the HD shop had it. They hope the new pump will be in by Friday. HD should give us something for the inconvenience.

ASOTO
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  #30  
Old 20th June 2007
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Bill2 Bill2 is offline
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Quote:
Originally Posted by btkicker View Post
Great work MWD!

I checked my '07 Roadster (same small tank, efi, and all) and it's wires are where your new re-routed wires are!

Why the hell did HD move the wires only on the Nightster? I smell a recall to re-route the Nightster fuel-pump wires back to the normal spot.

again, good investigating.
Might be a service bulletin but i don't think theres no way its gonna be a recall.
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'05 Standard 883/1200 touring conversion with: '07 XB heads with 8.8:1 c/r, dragtron II a/c, Caliber 2into1 five step header, rejetted to: 46pilotjet @ two turns,needle clip on 4th groove,185 main jet,twin tech high performance ignition, 30 tooth trans pulley, jagg oil cooler, forward controls, pullback type handle bars,memphis fats windshield, Corbin classic solo seat with back rest, 10" pillion pad, black progressive 412 shocks 12.5" H-D springs, progressive fork springs, vista cruise control, and relocated ignition & coil to a stainless steel home brewed mount between the cylinders. (Temp. runs around 165-180 degrees in town and 180- 210 degrees on the freeway running 70-90mph and it uses no oil in between 3000 mile changes.) GPS calibrated speedometer.
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