Back in 2004, or somewhere around there, HD issued a TSB about the EFI Touring bikes (I believe it was touring), related to a problem they were having with the Fuel Injector Wires being too short and breaking from the vibration of the engine. The break was with the copper wire only, and inside the rubber wire casing so that it was not visually obvious, but, with the break in contact, it was causing intermittent problems with the operation of the fuel injector...

Does anyone remember that TSB and does anyone have a copy of the bulletin that they can send me?

Thanks, in advance!

E

 

why do you need it if you know it? gently pull on the wires and if they are broken it will stretch a little and the casing will get a little lighter from stretching. i solder a new end on and cut the harness free for more slack. Mike

 

A local indy shop is trying to deal with a problem an '04ish bike is having that sounds similar to the symptoms of the broken wire. They are having a hard time figuring it out and have already done all kinds of fuel system related repairs with no joy. I was talking about this TSB I saw a while back to the owner of the bike, but, the shop told him they didn't think it could be a wire problem despite having done all kinds of other things with no results. So, I wanted to find the bulletin to kinda prove my point.

 

Had it happen to my bike last year. Could not find it and was checked several times. The wire was actually broke inside the connector.

 

I had an '02 FLHTCUI that would occasionally misfire. This happened for about a year before the dealer found the problem. It eventually threw a DTC code and the found the wire to the front injector was broken. IIRC the wire was broken inside of the insulation and was the result of the wiring harness being to tight or the wires being stretched. The repair bill states: Diagnose & Repair Broken Wires at Front Injector
Connector 84B - Labor Code 7825 - $73.93. The repair was done in June 2004. I hope this helps.