Roadie sputtering

[LuisB1000rr]

Hi everyone, I'm a new member and happy to be part of the family. My bike has been driving me crazy for the past couple days. It started with what seemed like a misfire that progressively got worse the more I rode it to the point where it was unrideable. I tested for spark at the secondary wire plugs and had spark. Today I found the throttle body felt loose and was able to move it up and down with ease. I'm assuming I have a vacuum leak, I inspected the boots of the intake manifold and they are stripped and almost falling apart. I sprayed a shot of brake cleaner at the supposed area and confirmed the leak. I was able to remove the throttle body and the intake with the boots attached to the intake and not the flanges on the cylinder heads. Is this my problem? I went to partzilla and saw that the flange with the boot is one piece and they are a little pricey. Can I use silicone to seal the boots back on? Is there an alternative? I'm a newbie and would appreciate any advice given. Thank you.

[Brad_G]

from Solon, IA

Yes it does appear they are very proud of those parts. Since this is all molded together as one part I don't think you're idea of trying to silicone/glue them back together is going to work.

[Father Pobasturd]

Representing Scorpion Gulch, Arizona. I ride a dinosaur (carburated) so I'm no help to you. Good luck with your issue. Seems pretty plain as to what the problem is. Yea, the parts may be pricy, but these bikes require so little and give back so much it's hard to complain when they need attention. It'll be worth it.

[brianmac]

those parts get pretty hot,

[Mr. Miyagi]

from Texarkana, in the Arklatex

[Lug Nut]

I've never heard of the fuel injected roadstar having that specific problem before. I hate to say it but You're going to be much better off buying OEM new parts. Look up the exact part number you need go to eBay and see who has it the cheapest. Unless you like tearing all that apart several times I wouldn't even try to use silicone on it. What part of the country did the bike come from? Can't imagine it getting that hot just sitting there I believe it'll shut itself off after 20 minutes?

[Shores]

I have a 2008 also. I agree with lug nut. You're wasting your time trying to repair it. Just consider the money you've already saved by owning a road star instead of a Harley, bite the bullet and get the OEM part. I can count the problems reported on this forum with fuel injected road stars on one hand. That problem is not one of them. Why do you think the parts separated?

[LuisB1000rr]

Sorry for the long delay. Between school and work my time is basically 1 day a week and have lots of homework.
I got the OEM intake boots and bike runs good until gets warm, then starts sputtering again and backfire from intake.
Checked fuel pressure and it's @ 55 psi until warm, then pressure drops to less than 30 psi and the sputtering starts again.
Believing it's a bad pump I think I should order one.
Voltage to the pump is 12v all the time
Anything else I should test before ordering the pump?

[Shores]

If you have an aftermarket fuel processor, that may be your problem. It's the most common problem with fuel injected road Stars. People are told by the dealership that they need the aftermarket processors if they change the intake or exhaust and that is not true. The stock fuel processor works just fine and will adjust. Let a few let us know if you have an aftermarket fuel processor

[LuisB1000rr]

No aftermarket fuel processor

[Shores]

Has it been sitting for a while which would allow the ethanol fuel to turn to gel. Have you run a strong batch of Sea foam or techron plus concentrate through the tank to clean out any old fuel?

[LuisB1000rr]

Tank was cleaned and it's very clean inside, fuel is new.

[Lug Nut]

Hate to tell you this but you need a $600 new in tank fuel pump it sounds like. With pressure drop off that indicates a cracked housing or a bad pump.

[LuisB1000rr]

Now, why the pressure is good until bike warms up?

[Shores]

I would look for air leaks in the exhaust or intake before I would jump to the conclusion that it's a fuel pump issue. How many miles on the bike? Issues with fuel injected road stars are extremely rare. I think I've heard of only one fuel pump issue in the 11 years I've been on this forum. Having a clean fuel tank and new fuel doesn't mean that there isn't gunked up fuel elsewhere in the lines, injectors, etc. Has the bike been sitting for a while and how many miles do you have on it?

[LuisB1000rr]

Bike was sitting for a while, like I said the tank was cleaned and it's very clean right now, like new.
The fuel filter was desintegrated and I added a new one.
What's bothering me is the fact that before warms up everything is fine, the bucking and hard miss starts after warms up
Now with gunked injectors will be running bad doesn't matter if it's cold or warm
Hot computer will drop the voltage to the pump, voltage stays at battery voltage at the pump
Pump drops from 55 psi before warming to between 20 and 30 after warming, for me that's an indication of a bad pump.
I may be wrong but that's my logic

[D-Fresh]

Even if it is a pump, someone on the forum found a aftermarket pump and for approx $50 and rebuilt the original one so don't crap your pants yet!

[D-Fresh]

This is one i found a while back and there is a write up with pics someone will find IF, you need to go down that road.

[Shores]

While running, spray starter fluid around your intake manifold to see if there is a leak. If there is, the RPM will increase. Have you cleaned your injectors and the fuel lines?

[LuisB1000rr]

I have a concern.
The pressure regulator is not vacuum controled, it's atmospheric.
I dont see a reason for the regulator to change the pressure but maybe?