Motorcycle Repair Questions, Solutions & Tips Page 6 - Vr2020

Motorcycles - Page 6 - Recent Questions, Troubleshooting & Support


Hi, Rgjscass before inspecting your points you will need to remove the spark plugs and timing hole plug if you have electric start only, you will need to get the rear wheel off the ground about 2 inches and put the bike in first gear for bumping the engine over. Refer to your service manual for the proper timing marks on your flywheel for your particular year and model as Harley made several changes over the years. Remove the points plate cover, the 2 points plate stand-off studs, the points and points plate, the center points cam bolt, and finally, the mechanical advance mechanism paying close attention to the locator pin on the back side of the advance mechanism and the corresponding machined slot on the end of the camshaft that it fits into. Inspect the advance mechanism carefully look for weak, almost or broken springs, worn advance pins, and wobbly weights due to egg-shaped mounting holes, replace defective parts as necessary, lubricate flyweights mounting holes/pins/springs with a small shot of WD-40. If you have any doubts about the integrity of the advance mechanism replace it with a new one. Next carefully inspect the points look for pitted contact surfaces and refurbish with a point file or 220 grit or coarser folded sandpaper, if necessary, inspect the rubbing block for excessive wear if in doubt about condition replace with new points and new condenser, I recommend Blue Streak Points Kit. Carefully install advance mechanism, points cam with flat side behind the limit pin, and center bolt tighten to 70-inch pounds. Install points plate, points, and condenser, snug stand-off screws and using an ice pick or similar device stake the points plate on the edges in three different spots, this procedure is very important as it will keep the plate from becoming eccentric during timing procedure. Next bump the engine over until the points rubbing block is on either the fat or skinny cam lobe and insert a .018" flat blade feeler gauge in between the points slightly loosen the points adjusting screw and set the point cap so you can remove the gauge with a slight drag, bump the engine over to the other cam lobe and measure what that gap is because they are supposed to be the same, but rarely are. Now comes a little finesse on your part you need to bump the engine over to the lobe with the widest gap on the points and take a measurement in between the points forget about the .018", using a small hammer and a flat punch lightly tap the center bolt from the top once this will lower the cam lobe closing the point gap and raise the other cam lobe thus opening the points slightly more, then bump the engine over again to the other lobe a take another measurement, you need to get cam lobe measurements identical to within .004" or better this is "VERY" important as it determines when the front and rear cylinder fire. When you get the measurements as identical as possible example .012" on one lobe and .010" on the other adjust your points on any lobe to 018" and lock it down. All this may seem petty but I can assure you it makes all the difference in the world when it comes to starting, idling, and performance, trust me. Now that you have the spark plugs firing correctly to each cylinder you need to statically adjust when they fire, to do this get the front cylinder advance timing mark dead center in the timing hole window by bumping the engine with the rear wheel, at the top of the left crankcase for Big Twins the right crankcase side for Sportsters, spray Brake Kleen on the mark to remove any oil film let dry then paint the flywheel and timing mark with red nail polish and let dry, this will help you greatly when it comes time to use a timing light. Next bump the engine slowly until the top dead center mark is in the timing hole dead center, loosen the standoff studs and rotate the points plate until the instant the points start to open, use a test light for accuracy clip the line to ground and wedge the point of the light to the electrical connector on the points turn on the ignition and the kill switch to run, when the light comes on the points have started to open snug down one stand-off stud. Next turn off the ignition and put the bike back in neutral, lower the rear wheel back on the ground, drain the oil tank into a clean container, replace 16 oz. of the oil, this is plenty to lubricate the engine and limit the oil and breather blast that comes out of the timing hole when using a light. Next use a sandwich bag or Saran Wrap and a rubber band over the end of the timing light lens, connect the timing light to the front cylinder spark plug with the bike in the upright position start the engine and let idle for 1 minute, set RPM'S to 2,000 have someone remove the timing plug being careful not to be in direct line of breather/oil mist spray, hold timing light directly in front of the hole you should be able to see the nail polish front cylinder advance timing mark, if not loosen the stand-off stud and adjust the timing plate until the red nail polish come into view, you want the mark dead center in the hole, when you get that position lock down both timing plate standoff studs and shut off engine, replace timing hole plug and remaining engine oil, adjust idle to 1,000 RPM and if necessary air-fuel mixture screw on carburetor. For more information about your issue please and valuable "FREE" downloads that you will need please click on the links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have nice a day.
How to set the points and timing on an old Harley Big Twin
https://www.carlsalter.com/mcpdf/Harley-davidson-1948-57%20EL_FL%20service%20Mejor%20tinta.pdf
https://www.carlsalter.com/mcpdf/Harley-Davidson-1941-84%20FL%20Models%20Parts%20Catalog.pdf
https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm free owners manual
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Harley Davidson... | Answered on Oct 16, 2018


Hi, Mark and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, stator, magneto, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Faulty or corroded kill switch.
11. Accelerator pump damaged or not working.
12. Water or dirt in the fuel system, carburetor or filter.
13. Restricted, blocked or kinked fuel line.
14. Fuel tank empty.
15. The gas cap is not venting properly or fuel tank venting system blocked, loosen gas cap and go for a test ride.
16. A failed fuel pump, pressure regulator and or fuel injectors.
17. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
18. Needle and seat stuck closed in the float bowl.
19. Petcock clogged or damaged.
20. Lean angle switch is faulty or needs adjustment.
21. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
https://www.reddit.com/r/Harley/comments/35afwv/bike_just_randomly_dies_out_while_riding_and
Bike shuts off while riding WTF Harley Davidson Forums
84 to 98 FL FX Harley Service Manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm free owners manual
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Harley Davidson... | Answered on Oct 16, 2018


Hi, Crashhawk1 and the usual suspects are:
1. Severely discharged or a damaged battery must have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Faulty alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Faulty main circuit breaker or ignition switch, check for loose connections and continuity.
5. Faulty system relay or ignition relay, check for continuity.
6. Faulty ignition coil, ignition/electronic module.
7. Faulty CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Fuel tank empty
11. Fuel tank contaminated with ethanol sludge.
12. Water or dirt in the fuel system, or clogged filter.
13. Quick disconnect check ball stuck.
14. Restricted, blocked or kinked fuel line.
15. Faulty fuel pump.
16. Faulty pressure regulator.
17. Faulty or clogged fuel injectors.
18. Lean angle switch is faulty or needs adjustment.
19. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
02 injected Softail starts then dies Twin Forum Harley Davidson Forums
2004 Harley Touring Service Manual pdf
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2005 Harley Davidson Road King Classic EFI Owner Manual
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2004 Harley... | Answered on Oct 16, 2018


Hi, Skipglide the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Harley Davidson... | Answered on Oct 16, 2018


Hi, Bestwaytrans and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Improper valve clearance (too tight)
17. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
18. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
19. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
20. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
21. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
22. Faulty neutral, clutch, kickstand safety switch.
23. Faulty fuel pump.
24. Faulty pump relay or fuse.
25. Faulty ignition system relay.
26. Faulty or corroded run/stop switch.
27. Tilt sensor needs a reset.
28. Security system not disarming alarm needs a reset.
29. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Harley Davidson Softail Won Start 2007 Harley Softail Service Manual pdf http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc 2007 Harley Davidson Softail Deluxe Owner Manual Instant Repair Help over the Phone to speak to me personally $4

2007 Harley... | Answered on Oct 16, 2018


Hi, Anonymous and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Spark plugs in bad condition or partially fouled.
4. Spark plug cables in bad condition and leaking check for spark leakage in the dark
5. Spark plug gap too close or too wide.
6. Faulty ignition coil, module, and or sensor.
7. Loose, dirty, or corroded ignition module connector at crankcase.
8. Faulty CKP or CMP, MAP, ETS, ATS, TPS, O2 sensor.
9. Dirty air filter.
10. Intake air leak.
11. Water, dirt, or rust in the fuel system.
12. Carburetor contaminated, sticky float, plugged jets.
13. Carburetor has oil in the bowl due to excessive oil in pre-mix.
14. Carburetor vacuum diaphragm torn, cracked, not seated or installed improperly.
15. Multiple carburetors out of sync.
16. Fuel filter clogged.
17. Old or contaminated fuel.
18. Fuel tank vent system plugged or carb vent line closed off.
19. Gas cap diaphragm valve faulty.
20. Vacuum line from intake manifold to fuel valve is broken, cracked, pinched, or missing.
21. Carburetor controls misadjusted.
22. Incorrect valve timing.
23. Valve springs floating, weak, or broken.
24. Damaged intake or exhaust valve.
25. Incompatible performance parts.
26. The control module may be in "LIMP" mode
27. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Engine misfire and hesitation Harley Davidson Forums 84 to 99 Harley Softail Service Manual pdf http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm free owners manual Instant Repair Help over the Phone to speak to me personally $4

1993 Harley... | Answered on Oct 16, 2018


Hi, Tgolovio oil leaking from your air cleaner is caused by oil carryover from the engine. For whatever reason, the breather system is not separating enough oil mist and air from the piston downstroke. There are cheap and quick easy fixes and there are more expensive ones. First, make sure your breather hoses are not dry-cracked-pinched if they are ok you can start by trying the following:
1. Run your oil level half way between the add and full mark when hot.
2. Run oil breather lines from the head into a TEE fitting below carb/induction module then a single line into a mini filter or PVC valve under the frame.
3. Purchase Arlen Ness Super Sucker.
4. Replace umbrella valves and realign oil pump.
5. Replace piston rings and follow proper driving seating procedures
6. Upgrade oil pump and cam plate.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
oil leak air cleaner Harley Davidson Forums 84 to 99 Harley Softail Service Manual pdf http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm free owners manual Instant Repair Help over the Phone to speak to me personally $4

2000 Harley... | Answered on Oct 16, 2018


Hi, Peter for more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
https://www.bowkerlifestyle.co.uk/harley-davidson/harley-davidson-parts/harley-davidson-security-and-storage/chrome-bungee-nuts-1750933323
2010 Harley Softail Service Manual pdf
http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
2010 Harley Davidson Fat Boy Owner Manual
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2010 Harley... | Answered on Oct 16, 2018


Hi, Rick and the usual suspects are:
1. Extremely lean fuel mixture.
2. Dirt, rust, water, or ethanol sludge in the fuel system.
3. Sticky throttle cables.
4. Multiple carburetors not in synchronization.
5. TPS sensor out of adjustment or faulty.
6. Wrong spark plugs for the type of service.
7. Throttle bodies not in synchronization (FI)
8. Faulty O2 sensor.
9. Clogged, stuck, or faulty IAC valve.
10. Aftermarket components not compatible with ECM.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://forums.cycleworld.com/archive/index.php/t-131716.html
Idle problem with my GSX 600F Suzuki GSX Motorcycle Forums Gixxer com
Suzuki GSX600 Katana 1989 1997 Workshop Service Repair Manua Download... $15
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1996 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Andremich647 for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2006 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Anonymous the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Suzuki GSX600F Service Manual
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2000 Suzuki GSX... | Answered on Oct 16, 2018


Hi, James after careful deliberation 4 out 5 Suzuki Gods give this one a thumbs up, but just to be on the safe side you should give your local dealer's parts/service department a call to confirm.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1990 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2006 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Anonymous the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day
Suzuki GSX600F Service Manual
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1999 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1993 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Michael for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2001 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Fburpee for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2005 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2006 Suzuki GSX... | Answered on Oct 16, 2018


Hi, Corrie for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
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2012 kawasaki... | Answered on Oct 16, 2018

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