...and another "oh", I replaced the crank position sensor after reading it could be the culprit. $90 down the drain.

 

Solution? Better idea?

 

i see you got gravity fuel flow. While I have never heard an explanation for why, many mysterious no starts have been cured by removing the fuel quick disconnect on the bottom of the tank and reinstalling it. No extra charge to try it.

 

Ironically mine was running just the other day, but when I siphoned tank and remove the nut holding what I presume you're calling the fuel quick disconnect on the bottom of the tank and re-installing it, NOW it won't start but just cranks and cranks and cranks. Not a hint of starting. So, not sure if I would try that! Seriously though, maybe, but I have the opposite problem. I've had nothing but problems with this bike and am oh so close to selling it as I've missed the last 3 summer vacation on it due to blown top end first and then a blown NEW crank that literally broke in half and stranded me in the middle of the country after 6000 km on the new crank. It just never seems to end though I'm thinking this just has to be minor. But it still means I have to take my backup KTM Adventure on a huge cross-country trip it's not really meant for and I won't have the comfort of the Harley or it's stereo. My God it's a frustrating machine.....ah here we go just the emoticon I needed .

 

My apologies to my Harley as it was entirely my fault. Dave of LOVE JUGS knew what was wrong as he'd done the same thing himself so knew exactly what I was talking about. Apparently, disconnecting the fuel line is as easy as pushing up on the round chromed collar that's just below the large chrome nut I loosened/tightened. Like an air hose fitting type of collar where you push up and then pull down to disconnect the line. This is apparently the 'quick disconnect' you spoke of that I didn't even know was there.

By not knowing that and simply frigging with that nut I twisted the hose or whatever inside the tank like a pretzel and either broke it (likely) or it's so frigged up that fuel won't flow through it to get to the injectors. Or something like that. So, assuming that is indeed the problem I'm going to re-siphon, QUICK DISCONNECT the line using the collar (wish I'd had a service manual or maybe if in the owner's manual which it likely isn't then I wish I looked in there but I was sure it wouldn't be as that's not something usually in the owner's manual) which is maddeningly simple and wish I'd known that in the first place. THEN I remove that nut and look inside to see what I did and see if it's ruined and needs replacement. He said it's not expensive, rather it's very cheap, but is a pain and again means no trip for Harley this year but am on an adventure tourer for a continent crossing trip. On the bright side, this backs up my lame justification for having a KTM 990 Adventure AND a Harley anyway, I did tell my wife it's good to have a backup bike. I also said it makes sense to have two bikes because then each bike lasts twice as long and needs half as many repairs.

This is my second contact with LOVE JUGS and these guys are just phenomenal for customer service. I mean I was desperate so asked them even though this was not an issue with their product, and he answered near immediately. He gave me his number and when I called he spoke with me for 10 minutes or more to help. That alone makes me assume that the LOVE JUGS will be awesome or at least will have top notch support. Impressive to say the least and I wish all companies acted like them.....now that's how to run a company and get the word out about their products.

 

It's very important to check the service manual before you put a wrench on your bike. As you've learned, that check valve has a flexible fuel line attached to it, and the other end of the fuel line is attached to the regulator inside the tank. If you try to remove the check valve without removing the top plate on the tank, and disconnecting the fuel line from the regulator, you will just twist the fuel line like winding up a rubber band on a toy airplane.

All of us who work on our own bikes have made bonehead mistakes like that. There's nothing that you will break that can't also be fixed.