2002 FLHRI Has my mechanic stumped! - Harley Davidson Forums: Harley Davidson Motorcycle Forum
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Old 11-18-2011, 10:52 AM   #1 (permalink)
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2002 FLHRI Has my mechanic stumped!

I sure hope there might me a HD tech monitoring this forum 'cause we have a problem we can't seem to solve.
2002 FLHRI 69,000 miles. No tuner.
Here's the deal: Bike has run fine for last 8 years except for a couple of times it ran rough, wouldn't Idle but cleared itself up in a few miles. Then, I started down the onramp to the interstate and just as I merged into traffic, it backfired a couple of times, coughed and started missing. I crossed over the median and limped back home. Pulled the plugs and the front plug was fouled black like too rich. Back plug was ok but too black for normal. I happened to keep last set of old plugs and compared them. Old ones nice and gray/brown color. We checked for an engine code. None. Pulled the tank off and emptied it and cleaned it out. Fresh Shell Premium gas. Now, about every 5th or 6th start-up it won't idle properly. Runs rough, exhaust smells rich, won't set a code. Checked injector wiring. The shop that has the bike is an independent but owned and operated by HD factory trained mechanic. All his mechanics are stumped. They called all the HD shops in our area and none have suggestions. One possibility, Idle Air Control??

Does anyone have any suggestions or ideas?

Has anyone else run into this problem?

I sure do need some help. The bike has been down now for two weeks and we are all pulling our hair.
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Old 11-18-2011, 09:48 PM   #2 (permalink)
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I am wondering if the ECM might possibly be the culprit? Has anyone encountered ECM failure with any of the Twin Cams in 2002 and up?
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Old 11-18-2011, 11:25 PM   #3 (permalink)
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maybe you got an injector sticking and in that case it would supply to much fuel. just a thought.
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Old 11-19-2011, 07:04 AM   #4 (permalink)
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You can test the IAC . Remove the air cleaner to get a better view of the IAC air passage , now cycle the ignition on and off while observing the IAC plunger thru the hole at the top of the throttle body intake . If the IAC is functioning correctly you'll observe the IAC pintel cycling in the air passage , it should cycle consistently ... in - out - in - out .
Wait 10 seconds between cycles or a code could get set .
Another thing that could cause your symptom is a faulty / failing CKP which might not set a code . The CKP can also be tested . Disconnect the CKP connector and test ohms across the two pins , it should read 1000 ohms give or take a few . If out of range it would become intermittent .
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