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post #1 of 125 (permalink) Old 10-05-2012, 10:59 PM Thread Starter
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problem starting

Three times the charm? No. I got the bike from the dealer, they said it's all good now.After replacing, plugs, wires, ignition module 4 weeks in the shop they say it's ready. Third time picking it up. they brought out the bike and it started without the choke, perfect just a dream I took it and needed to fill up. Stopped at the gas station 2 miles away from the shop. Filled up and shit! it won't start. Crank crank, nothing 3,4 , 10 tries nothing loud bang from the pipes and blue smoke from the carb. I started pushing it to the parking space and I pressed the start button - brrrrrrmmm perfect start and idle. I took it home 10 miles away. Killed the engine and restarted it -perfect, second time perfect. I parked it and this afternoon tried to start it and it did a little rough but it did. I ran it 2 miles and shut it off, tried to start it and nothing, cranks cranks strong crank and bammm loud backfire. I tried again and it started "catching" but died and again it started and ran super fine. I dont know what the hell! Dealer replaced all those parts, they also said they put on a used known working coil (I dont trust them) Bike went in for strong backfiring 4-5 times a day and starting issues. 500 bucks later they dont want to see me or the bike. I called the HD in Milwaukee to complain they told me there is very little they can do. I don't want to deal with the dealer anymore I want to get to the bottom of this and fix my bike. It has VH pipes with open filter. Carb was jetted by the previous owner and the bike ran super fine for 4 months untill one day when it started to backfire and having starting issues. Also I notice that when I start it or it idles, there is very little gas pressure coming out of front pipe a lot more from rear, once I hit the throttle it puts out lot more pressure same as the rear. Please help.
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post #2 of 125 (permalink) Old 10-06-2012, 06:11 AM
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Those symptoms sure sound like a faulty cam sensor (ignition pickup) to me !
Also I would take a compression test when the engine is acting up to verify the valves aren't hanging open. Carboned up valve guides that swell up when the engine gets hot and hang the valves up.

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post #3 of 125 (permalink) Old 10-06-2012, 06:12 AM
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Oh yeah, Sportsters are notorious for ignition switch failures too.

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post #4 of 125 (permalink) Old 10-06-2012, 06:46 AM
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When you turn it off, are you using the run/stop switch? If so, check it carefully for intermittent contact. I've seen bunches of run/stop switches get flaky. Try switching it on and off several times.
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post #5 of 125 (permalink) Old 10-06-2012, 07:48 AM Thread Starter
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BobF I shut it off with the on off switch. I will try to wiggle it to see if the probelm fixes itself. Should I take apart the switch housing and inspect the connection for burnt terminals and others?
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post #6 of 125 (permalink) Old 10-06-2012, 07:49 AM Thread Starter
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my bike has only 11K miles, I hope it's not carboned.
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post #7 of 125 (permalink) Old 10-06-2012, 08:19 AM
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When I get a bike in my shop and I'm told the bike has been to the dealer/dealers multiple times for the same symptoms I don't take anything for granted. I start with the basics: battery, fuel, spark, timing and compression.
If you've had the grips replaced then I would remove the clutch and brake lever clamps to inspect the wiring where it goes into the switch housings.
Also you said the shop replaced the module, did they replace the cam sensor pickup ???

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post #8 of 125 (permalink) Old 10-06-2012, 08:32 AM Thread Starter
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as far as they told me only the module was bad and the bike was running on one cylinder (BS because I ran it 12 miles to the dealer and only backfired few times) they said all other components tested OK.
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post #9 of 125 (permalink) Old 10-06-2012, 08:44 AM
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Try to determine if the pickup inside the round cover located on the cam cover was replaced. The symptoms you describe perfectly match a faulty pickup. Look at your repair order and post the P/N for the module they replaced.

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post #10 of 125 (permalink) Old 10-06-2012, 09:28 AM Thread Starter
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Here's what it says. Ignition Module Intergrated SE 32465-98B. The bike had Crane Hi something ignition installed before. Invoice also states that they installed New Plugs and Wires as well and the Ignition Switch Kit, FLAT 71441-94 since the old one was loose and key would sometimes "catch" and sometimes it would not.
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