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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #21  
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Here's the Sportsterpedia page on Sensors - Including the CKP - It is very important:
http://sportsterpedia.com/doku.php/t...shaft_position

And here's the page on Ignition Modules & Coils:
http://sportsterpedia.com/doku.php/t...k:evo:engctl01

The Coil can cause the same issue from heat. I would certainly try the hair dryer test on the coil.

But it is concerning that the ICM fails with heat. They are usually decent quality (except the nosecone versions in high heat) and we only look to replace them as a last resort, but they do fail.

Heat can sometimes cause connection failures - so do check the CKP connector as Paul mentioned but also the connections of the ICM itself. Pull off the ICM connector & make sure each pin is fully seated and not backing out of place when pressed onto the ICM.

Just as a regular maintenance action, you should always check & tighten your battery connections & your Powertrain Ground:

When you're having issues with the electrical system, use this Sportsterpedia section about checking the battery cables, voltages and grounds:
http://sportsterpedia.com/doku.php/t...place_to_start


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  #22  
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Thanks for the wealth of information!
I cleaned and reattached the crank position sensor terminals and cannot recreate any of the symptoms with the “blowdryer” test on either the coils, ICM, or the sensor.
However, I still managed to shut down in a half mile after warming up the bike (couldn’t keep up going into 3rd gear, shifted down, and broke down). Once cooled off, it started up like a champ.
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Time to check for DTC's.
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If it fails consistently enough, you can use Cold Spray to test in reverse - wait until it fails -

spray the coil - test to see if it fires up

if not, spray the CKP sensor - test to see if it fire up

if not, spray the ICM - test to see if it fires up

Since the bike restarts after cooling down, using the Cold Spray should allow you to determine exactly what device needs to cool down before it works again.


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Originally Posted by tamaro View Post
Thanks I’ll definitely check the crank position sensor! Shouldn’t I get a diagnostic trouble code if the sensor is faulty though?
To my surprise, the only codes I got were that my Turn signals were disconnected.
It doesn't always throw a code, it's usually intermittent. One of the main symptoms of a bad sensor is trouble idling when hot.
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I installed a new sensor... still shut down after warming up for 4min and had trouble turning back on.
However, cooling the ignition coil or ignition control module with compressed keyboard cleaner didn’t work either. Not sure if there’s another “cold spray” I’m supposed to use for that test, or if I have to give in and turn the bikenover to a mechanic.
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I was referring to something like this:




(Click the Image for linking to Amazon.com)

Maybe you can find something equivalent at your auto parts store -

When it fails, did you actually test to see if you're getting spark?
Did you do a manual spark test, triggering the coils manually?
http://sportsterpedia.com/doku.php/t..._testing_spark

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Originally Posted by tamaro View Post
I installed a new sensor... still shut down after warming up for 4min and had trouble turning back on.
However, cooling the ignition coil or ignition control module with compressed keyboard cleaner didn’t work either. Not sure if there’s another “cold spray” I’m supposed to use for that test, or if I have to give in and turn the bikenover to a mechanic.
4 minutes doesn't seem enough time for anything but the heads to warm up. Have you checked the spark plugs and/or ignition leads ?
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The spark plugs seemed alright, spaced and installed them <9,000 miles ago. And now apparently my 6mo old Harley battery isn’t holding charge.
Testing the voltage seemed to indicate that the stator and regulator/rectifier were functioning, so I’m at a loss �� I’ll be buying some freeze spray as per the recommendations above and also re-inspecting the leads/spark plugs
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