Odd Issue "Solved"

[sideshowBob]

Well after almost six seasons of 100% trouble free riding on my tuned from new SW it finally has an issue.
After a great high mileage ride yesterday my SW quit when stopped at a roadway for no apparent reason.
Details:
- 65 miles since refuel
-1/2 tank of fuel on gage
- 6'c/43f
-ok snow conditions with scratchers down and BOP aux radiator fan running
-sled temp normal@ 170f
-6500 header tuned miles, closed loop, adjustable fpr, hurricane big fuel pump, fuel return over slipper, fuel pump direct power harness, two fuel tank vent lines
-could here fuel pump cycle before it restarted
-fuel pressure gage indicated normal key on pressure before restart

Unfortunately I wasn't data logging!

NO CODES

After a short wait the sled fired right up and ran normal for a couple miles then quit again and this repeated one more time until it got me home and in the shop. Definitely seemed fuel related to me.

I have reviewed the " Three gallons or less" running issues thread for some ideas.

I plan on systematically step by step perform the following to see if any one individually has an effect or cure:

- drain the tank and add only one gallon of fresh fuel and see if it runs or repeats
- replace the fuel pump relay with another sealed one I keep as a spare.
- bypass the aftermarket pump relay harness and go back to stock wiring connection
- check the fuel pickups and fuel pump hoses
- change out the fuel pump for one I have as a spare [Deatschwerks 9-201-1000 255 lph]

Hopefully that process will track down or at least eliminate the fuel system as a possible issue.

I guess I will pull out my trusty Yamacharged Attak for my next ride.

 

[Turboflash]

Juat thinking out loud ...
Any chance it could be start of problem with crank position sensor (possibly heat related)?
Agree could be start of issue w fuel pump?
Agree it could be beginning of issue with one of the relays in your fuel pump circuit?
However, usually the fuel pump is either off or on. If they're becoming intermittent, the engine would tell you that by starting to misfire, or run poorly due to low fp.
Any chance for a bare wire shorting someplace?

 

[twyztid]

Pull the fuel pump and check the wires on the underside of where they go through the plastic cover. I have heard of them breaking

 

[fatchance]

Pull the fuel pump and check the wires on the underside of where they go through the plastic cover. I have heard of them breaking

Yes, that and the stock pump connector fails also.

 

[sideshowBob]

My first thought when it quit was the crank position sensor but it has absolutely zero codes displayed or detected on the Gap Flasher.

 

[sideshowBob]

I just drained all the fuel and put in 1/2 gallon or so of fresh 91 octane and it starts and runs no problem .I drove it around the property for quite a bit and it seemed normal so its not a fuel pickup problem...of course it never did quit.

 

[1nc 2000]

Check for loose battery cables at battery...
Handlebar kill switch?
Just my 2cents...

 

[sideshowBob]

Items eliminated as the cause of sled quitting:
-fuel suction
-tank venting
-battery or its connections
-voltage regulator
-fuel pump connections
-fuse box relay
-fuel return to tank

Question:

Has anyone had a stator or pickup coil issue without it throwing a code?

 

[DMCTurbo]

You drained your fuel and put fresh fuel in and problem solved. Maybe that's your answer. Did you fuel up at a sketchy location?

 

[Fleecer]

Did it cough and sputter while riding? Usually a bad pump elicits some fuel starvation issues before quitting totally. This will show up on the FPR Gage as well as the datalog.

 

[sideshowBob]

Sled has run without a flaw or hickup for years until it just quit...started up and ran normal until it quit again....very strange indeed.
We did a 200 mile day ride and it used way less fuel then any other sled perfect until it wasn't.
Its too bad I wasn't data logging at the time.

 

[sideshowBob]

You drained your fuel and put fresh fuel in and problem solved. Maybe that's your answer. Did you fuel up at a sketchy location?

I fueled up at a remote restaurant but a very reliable guy got us fuel but who knows...there was five of us though and know one else had any issues.

 

[fatchance]

Did it cough and sputter while riding? Usually a bad pump elicits some fuel starvation issues before quitting totally. This will show up on the FPR Gage as well as the datalog.

Glenn I'm assuming you got your's corrected. What was your issue?

As you know the issue with mine was the faulty stock 2 pin connector going into the pump..... In my case the trigger for the relay to the pump.

 

[KnappAttack]

Check the fuel pump plugs. Happened to me in a field where it just quit one day riding alone in the middle of no where. The next day while it ran fine, went into a pit stop, shut it off and It would not start at all. I knew It had no fuel pressure or fuel pump, suspected it was a relay, warmed and swapped them out still no fuel pump. Friend came with the trailer and got me home. We took the seat off and found the fuel pump plug in completely fried. Cut off the stock plug ins, replaced with HD plug ins and been fine since.

 

[1nc 2000]

I also have found the electrical plugs to not have support for the wire coming out of the plugs into the wire loom.
A good sturdy piece of shrink wrap on the harness onto the connector would help...
The wires will bounce around and spread open the terminals over time.
I have had this cause issues.
Loose connections will also cause plugs to melt from sparks and heat.