07 Nightster Fuel Pump

[theoneandonlybrooks]

I've searched on here and found some stuff, but not quite the info I need.
I have an 07 Nightster, just bought a couple months ago, less than 4k miles when I bought it, now about 5k. Starting a week or two ago, when the fuel pump cycles at key on, it would squeal very loud, sometimes all through the cycle, sometimes just the beginning, sometimes at the end. Then one day when I went to leave work, I turn the key on, and the pump cycle sounded really quiet. Bike would fire twice then die. Did this several times, then finally on one of the pump cycles, it sounded normal, and started and ran. I rode it home, everything was fine, but since then, it's back to the quiet cycle, and 2 fires and die. So I think the fuel pump is out, but not 100% confident.
I've searched and read that the fuel pump is a common failure for my year. I have the A-model pump, and I have removed the complete assembly. But I'm wondering if I should replace just the pump, or the whole assembly, or if it's something different.
Also, I did check the relays, replaced the headlight and fuel pump relays, headlight still works fine, fuel pump acts the same.
Any help would be greatly appreciated, thanks.

[erbie07nightster]

Here is the Tech Tip that was released by HD. This route that might save you buying an entire new pump.

TT328 – August 9, 2007 – 2007 XL Fuel Pressure
2007 XL Pressure Regulator / Low Fuel Pressure
With the help of the dealer network we were able to isolate some recent no start and poor drive quality complaints caused by inadequate fuel pressure. On some ’07 Sportster models the fuel pressure has been recorded well below the service
requirement of 55-62 PSI. This finding lead us to the conclusion the pressure was bleeding down past the large pressure regulator o-ring.

In order to ensure proper positioning and minimize movement of the o-ring a new service kit has been introduced. Use labor code 7164 and order part number 61005-07, which consists of a “Castle” Washer, Filter Screen, 1 Small and 1 Large O-Ring and is
intended for use on 75268-07/A/B Sportster fuel pumps. The “castle” spacer is installed with the openings pointing downward to prevent fuel flow restriction and should be only added to 75268-07B or earlier XL fuel pumps. Inspection processes were put in place prior to 2008 model launch, and in late August of 2007 XL production will be making a running change to a 75268-07C fuel pump. These fuel pumps will not require the “castle” spacer. The original regulator service kit (p/n 61015-04A) will remain available for situations requiring regulator replacement, service of a 75268-07C fuel pump or service of an already upgraded -07B and earlier pump.

[theoneandonlybrooks]

Originally Posted by erbie07nightster

Here is the Tech Tip that was released by HD. This route that might save you buying an entire new pump.

TT328 – August 9, 2007 – 2007 XL Fuel Pressure
2007 XL Pressure Regulator / Low Fuel Pressure
With the help of the dealer network we were able to isolate some recent no start and poor drive quality complaints caused by inadequate fuel pressure. On some ’07 Sportster models the fuel pressure has been recorded well below the service
requirement of 55-62 PSI. This finding lead us to the conclusion the pressure was bleeding down past the large pressure regulator o-ring.

In order to ensure proper positioning and minimize movement of the o-ring a new service kit has been introduced. Use labor code 7164 and order part number 61005-07, which consists of a “Castle” Washer, Filter Screen, 1 Small and 1 Large O-Ring and is
intended for use on 75268-07/A/B Sportster fuel pumps. The “castle” spacer is installed with the openings pointing downward to prevent fuel flow restriction and should be only added to 75268-07B or earlier XL fuel pumps. Inspection processes were put in place prior to 2008 model launch, and in late August of 2007 XL production will be making a running change to a 75268-07C fuel pump. These fuel pumps will not require the “castle” spacer. The original regulator service kit (p/n 61015-04A) will remain available for situations requiring regulator replacement, service of a 75268-07C fuel pump or service of an already upgraded -07B and earlier pump.

Would that have caused the sound changes?

[erbie07nightster]

I would think it's possible. I have no problems with my pump, and it sounds different just about every time I fire it up. I notice it makes different noises if it's sat for a little longer than the last time. Or if it's a little different depending on the temperature outside, too. I'd say if you can get it to somewhere that you can have the fuel pump pressure checked and go from there.

[Screw Loose Dan]

I've actually heard of very few pumps actually go bad. The first year, there was problems with the pressure regulator (what the tech tip refers to), but other then that very few completely bad pumps (although initially before Harley came out with the actual tech tip, some dealers replaced the entire pump).

And yeah, the sound is a bit different from time to time. A squeal is not uncommon if it's sat for a while.

Since it sounds like you have the pump out, see the entire tech tip here and see if it has the "castle" washer or not. But, I would think it's a lot more likely that your relay is bad or some other bad electrical connection is causing issues.

[theoneandonlybrooks]

Originally Posted by Screw Loose Dan

I've actually heard of very few pumps actually go bad. The first year, there was problems with the pressure regulator (what the tech tip refers to), but other then that very few completely bad pumps (although initially before Harley came out with the actual tech tip, some dealers replaced the entire pump).

And yeah, the sound is a bit different from time to time. A squeal is not uncommon if it's sat for a while.

Since it sounds like you have the pump out, see the entire tech tip here and see if it has the "castle" washer or not. But, I would think it's a lot more likely that your relay is bad or some other bad electrical connection is causing issues.

When I bought it, it had likely been sitting for awhile, but it was my daily driver for a few weeks before the squeal. In fact the first time I noticed the squeal was on a ride from Springfield, Il, to Paducah, Ky. Rode down Saturday, when I turned the key on in my the hotel parking lot on Sunday, it squealed for the first time. So I'm very glad it at least made it home.
I don't want to take the whole bike to the dealership, because they said it would likely be 1-3 hours diagnosis and labor, which is closing in on the price of a pump itself.
It never had any issues when running.
The sound of the pump(how loud during key on cycle) seems clearly linked to the problem. Because it was always the same volume(sometimes including squeal) and would start, now that it's quiet, it's clearly not getting the fuel to run. So I'm wondering how the castle nut seal deal would cause the pump to be quieter.
And as far as the relays, like I said, I swapped the headlight and fuel pump relays, no change to either circuit.

[ProbablyBob]

The fuel pump in my '07 1200C started making this whining sound about 3 weeks ago though it only does it when it's hot outside. My early morning commutes and evening rides are fine. I know it has something to do with pressurization.

Some others have posted on another forum that they're experiencing the same thing. They say if they fuel up, the whining goes away. They also say that maybe the internal hose has a hole in it from rubbing the inside of the tank. Anyone heard of that?

[WinterWheel]

I've gotten this whine on several occasions, Usually, after a fill on 94 (I use 91). I've also had pretty good results with Lucas Fuel Additive. Generally happens after a hard run. With a hot engine. Even on priming.
Now, I'm starting to understand.
Although my Nightster is 2010, it does explain a lot.

[theoneandonlybrooks]

Originally Posted by ProbablyBob

The fuel pump in my '07 1200C started making this whining sound about 3 weeks ago though it only does it when it's hot outside. My early morning commutes and evening rides are fine. I know it has something to do with pressurization.

Some others have posted on another forum that they're experiencing the same thing. They say if they fuel up, the whining goes away. They also say that maybe the internal hose has a hole in it from rubbing the inside of the tank. Anyone heard of that?

I've never heard the whining when the bike was running, only when it primes at key on. It's possible it was happening and I just didn't hear it. But I deally doubt it because the whine is really loud.

[ProbablyBob]

Originally Posted by theoneandonlybrooks

I've never heard the whining when the bike was running, only when it primes at key on. It's possible it was happening and I just didn't hear it. But I deally doubt it because the whine is really loud.

I hear it faintly at highway speeds and it becomes more evident when I'm slowing down for a stop or going through town.