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Sportster Motorcycle Motor - Top End Discuss Sportster Motorcycle Top End issues. Rockerboxes, Valves, Cylinders, Pistons, Rings, Lift Rods, etc...

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  #1  
Old 6th October 2019
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mrkocol mrkocol is offline
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Default Running rough after heads change

I have an ‘09 XL1200C. I recently changed out both cylinder heads due to an exhaust bolt snapping off with no convenient option for removal.

Aside from it being time consuming, all went well with the change-out, except the following issues:

- oil leak at the pushrod covers
- when filling gas tank, bike has trouble starting; after getting it started, I can start it up instantly until the next fill-up

I solved the oil leak by realizing I missed the gaskets on the top of the push-rod covers, so I ordered new ones and took it all apart AGAIN to put them on. . Now, these problems occur:

- same full gas tank problem as before
- at speeds of 20-40 MPH, bike acts like I am closing and opening the throttle every 30 seconds or so; basically like it’s not getting fuel

Any ideas what the issues might be? It would be great to solve this myself since I have gotten this far, instead of resigning to defeat and taking it to the $tealer. Thanks in advance!
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  #2  
Old 6th October 2019
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Default

Fault codes might give you a clue.

For starters I would be checking everything related to the fuel system, like fuel pump, fuel filters, throttle body butterfly, injectors, intake manifold seals, sensors and what ever else is attached to the intake.
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Old 6th October 2019
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Default

Here's the Sportsterpedia section on the circuit breakers, relays & charging system:
http://sportsterpedia.com/doku.php/t...harging_system

Sportsterpedia Note:
Quote:
NOTE: The 2007-2009 model years have a significant history of corrosion and gunk collecting in the fuse/relay tray causing low-grade shorts and erratic electrical operation - This is especially problematic if the bike is left outside or operated in the rain. It's a good idea to check & thoroughly clean this tray at least every year (or 4 to 6 months if parked outside).

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  #4  
Old 6th October 2019
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Default

May sound dumb, but when filling tank, fuel from the other side with the gas nozzle aimed at the other inside of the tank. If it starts normal, then check your fuel pump/filter asm. If it is still hard to start, you may have sediment in your tank that's blocking the inlet feed, that gets kicked up everytime you fill.
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  #5  
Old 8th October 2019
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Might want to consider removing and cleaning the fuel injectors as it does sound lean
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