Hey guys,

Asking for help with this one. Got an 04 Fat Boy, currently 18K+ miles (modded when new with 95 ci, 10:1 comp, 251 cams, SE ICM, Mikuni carb, comp. releases). I've posted several times recently about my lifter/cam/chain tensioner replacement. BTW - The cam job (new tensioner, new lifters, 55N cams) sounds great...very quiet up top. However I haven't had the chance to ride it much because of a problem probably related to the 'bus er' codes I've been getting the last 1K+ miles.

History: Battery replaced at 3700 miles (Aug 04)...dealer said loose connection/regulator problem. Installed drag bars with internal wiring and a 2" tank lift at about 7K miles...all wiring thru 1 1/4" handlebars sealed in heat-shrink tubing...all wires/cables carefully tucked and tied under tank...left ties just loose enough to hopefully prevent vibration wear/shorts. At about 17K miles, I got the 'bus er' for the first time at a red light and the bike shut down. I was able to restart and get home but had to keep the RPMs up so it wouldn't stall. Dealer replaced the security module and it seemed to do the trick for a very short period but then the 'bus er' code returned...now every time I start it up. When it happens, it feels like I'm running on one cylinder (doesn't run smoothly) . Cranking the throttle a little will sometimes cause the code to disappear and the bike seems to run smoother for the moment when the code clears temporarily...but recently the code usually returns at idle all the time.

So I picked up the bike from my indy yesterday after the cam job. I listened to the bike start up at the Indy's....it started easily...the cams sounded great. I asked him about the 'bus er' that appeared as we started the bike. He had forgotten to chase that problem but said he didn't think it was related to the motor and is probably a ground out somewhere in another system. I told him I would look over the bike for shorts. He recommended I check the P, S, PS codes to start chasing this problem.

Loaded the bike and took it home...tried to start it, got the 'bus er'...tried starting with and without choke....will only start when choked...runs rough/weak for about 15 seconds and then turns off...will stall immediately if you try to apply throttle with or without choke...smelled like it was flooded....ran the battery down... charged it for several hours to get it above 80% (took 6 hrs with HD tender)...tried starting again...same BS!...pushed it uphill into the garage at 2:00 am...pulled muscle in calf!!...ugh!

The parts that have been replaced since 17K miles while chasing this 'bus er' and other problems include: SE ICM, factory security module, intake manifold sensor, crank position sensor, (all dealer suggestions) and most recently the cam/tensioner job. I replaced the stator 3 weeks ago with primary inspection/adjustments. My battery is about 4 years old. I put the tender on it monthly when not riding/offseason, but bike wasn't ridden much in the last year while chasing the cam/lifter meltdown. I know I will probably need a new battery in the near future, but this one still takes a full charge overnight on the HD tender and will crank the bike over at least 8-10 times before it needs another charge.

So where should I start? Do I need the electrical service manual? How do I bring up and read the error codes? I know you depress and hold the odometer button while turning ignition on puts it in diagnostic mode...but then what? The only things I can think of are bad electrical component, needs new battery and/or regulator, or maybe a worn wire from the handlebar job?

I would really like to ride this bike again! The last year or so the only 'riding' this bike does is in the back of my truck to/from the dealer/indy.

A pound of C-4, or some help is sincerly appreciated!!

Regards

 

Hey guys,

I got an update. Problem seems to be solved for now. I checked wiring on the bike...did not find any evidence of shorting. I checked and re-tied all the wiring around the battery and unplugged/re-plugged the 3 connectors under the seat. None of the components in front of the rear fender looked bad/weathered.

Buttoned her up and turned on ignition...no more 'bus er' code. One of the connectors under the seat was not fully seated. This may have been the problem or some oxidized pin contacts that needed some movement. Anyway, I'll keep my trips local for a while to see if the code returns when riding.

After 1+ year in the garage...it's real nice to have my boy running again!! Thanks all...