Engine Dies And Runs In Spurts

Sputtering and stalling(Fuel Injection)

Irratic running, surging and a hissing in the tank after the pump cycles.

There's been some issues with engines in the fuel injected models sputtering and dying at half a tank of gas for no apparent reason. One cause for this is a fuel line inside the tank that is rubbing on the inside of the tank and wearing a hole in the line. When the tank gets to about 1/2 full, the motor will sputter and stall. This could be the problem but the fuel level isn't a necessary part of the equation here. The engine needs fuel pressure in the area of 50 LBS to operate right and if the line is causing the fuel pressure to bleed off, you will have sporadic running and stalling as a result.
You can try adding gas to the tank and it will usually run better again indicating this problem but a fuel pressure test is the positive diagnostic procedure for this situation.
The fuel pump will have a different sound to it like a hissing or whistling when pressuring up at start up if this problem exists and you may see fuel spraying around inside the tank when the pump is pressurized.

If you remove the fuel pump fuse to diagnose this condition, the engine should start, then stall with the fuel pressure that is in the line normally. With this pin hole in the hose , the engine will not start after removing the fuse because the fuel pressure has bled off. It's another way of verifying this problem.

You can also hear the problem by opening the gas cap and turning on the key.You'll hear the fuel squirting from the line in a hissing sound.

Below is a pic of the line and what it looks like when it gets worn through.

The manual mentions how to remove the assembly, but it's not very clear, If you reach inside and actually push downward on the pump itself, it will then swivel downward which allows it to be removed fairly easily. It makes sense once you have it removed.
The pump, pickup, and fuel sender assembly all can pivot 90-degrees. With it at 90-degrees, the assembly goes in and out with relative ease.
Check the side of the corrugated fuel line for abrasions. They rub on the tank and can wear through causing poor running as shown above.

Here's some other fuel units from a bagger in the swing away position for removing it and other Harley lines like a deuce.

softailbabe · 08-03-2008, 08:53 AM

I had the exact same problem with my 2003 FatBoy .. I just replaced the line with the pin holes in it $30 for the line.

Dr. Doolittle · 08-03-2008, 10:27 AM

Boy, there's a lot going on inside that fuel tank! Lines with pinholes, cracked canisters. Where will it end?

DueE · 08-19-2008, 11:18 PM

Sputtering and stalling(Fuel Injection)
Irratic running, surging and a backfire....

That sums up what is happening to my 98 Road King Classic after about an hour of riding on a hot day. Had my 50K maint including gas filter, air filter etc...new battery, tires and hit the road but after riding for about 1 hr, it acts up like that. I had the fuel line checked, pressure tested at full tank, 1/2 tank...road tested twice, they worked on it for over 2.5 hrs...no trouble found and couldn't duplicate the problem. I left the shop and about an hour later as I was leaving the interstate, it sputtered - on the exit. Went to the HD shop, they rode it, no problem duplicated. It seems after it cools down I'm good for another hour. Has anyone had similar issue? I just heard "maybe coil, maybe ignition module....am at a loss and cut the vacation short.

The 1/2 tank full theory is out the window...it happened again after a fillup. Anyone have any similar experiences?

glider · 08-23-2008, 01:18 PM

It's not necessarily at half tank, it's just that it is easier to locate at half a tank due to the gushing of fuel sound with the cap off.

hdrick01 · 08-24-2008, 09:01 AM

I have the same problem with my 01 fatboy FI. How do you replace the line?
hdrick01

glider · 08-24-2008, 09:04 AM

It comes out through the top plate on the tank. Replace the gasket AND the bolts that hold the cover, they have a sealant on them.

hdrick01 · 08-24-2008, 09:13 AM

Thanks for the quick response, glider. I'll take a wack at it today.
hdrick01

hdrick01 · 09-28-2008, 05:03 PM

I have a 01 fatboy. I followed Glider's instructions and boy what I found.
1) The line from the fuel pump to the fuel filter was fine, but the line from the petcock to the fuel regulator had 3 pin holes in it.
2) The tank liner inside the tank had cracked and pieces of the lining were all inside the tank.
So, when replacing the line (lines) be sure to replace the filter.
When purchasing the filter the line comes with it (fuel line kit)
When replacing petcock line the petcock comes with it (kit).
It's a relatively simple job, just follow instructions (ask dealer for interior tank parts pic and parts numbers) if you don't have a repair manual.
Hope helps anyone that has the same problems.
Thanks again to you Glider
HDRick01

glider · 09-28-2008, 05:07 PM

Glad it helped you out.

08-03-2008, 08:53 AM	#2 (permalink)
softailbabe New Family Ride: 2003 Fat Boy FLSTFI Join Date: 2008, Aug 03 Posts: 1	re: Engine Dies And Runs In Spurts I had the exact same problem with my 2003 FatBoy .. I just replaced the line with the pin holes in it $30 for the line.

08-03-2008, 10:27 AM	#3 (permalink)
Dr. Doolittle Contributor$ Ride: 2008 Street Glide Join Date: 2008, Feb 02 Location: Woodstock, Georgia Posts: 1,459 My Mood:	re: Engine Dies And Runs In Spurts Boy, there's a lot going on inside that fuel tank! Lines with pinholes, cracked canisters. Where will it end?

08-19-2008, 11:18 PM	#4 (permalink)
DueE New Family Ride: 1998 Road King Classic Join Date: 2008, Aug 19 Posts: 2	Engine Dies at Half A tank Sputtering and stalling(Fuel Injection) Irratic running, surging and a backfire.... That sums up what is happening to my 98 Road King Classic after about an hour of riding on a hot day. Had my 50K maint including gas filter, air filter etc...new battery, tires and hit the road but after riding for about 1 hr, it acts up like that. I had the fuel line checked, pressure tested at full tank, 1/2 tank...road tested twice, they worked on it for over 2.5 hrs...no trouble found and couldn't duplicate the problem. I left the shop and about an hour later as I was leaving the interstate, it sputtered - on the exit. Went to the HD shop, they rode it, no problem duplicated. It seems after it cools down I'm good for another hour. Has anyone had similar issue? I just heard "maybe coil, maybe ignition module....am at a loss and cut the vacation short. The 1/2 tank full theory is out the window...it happened again after a fillup. Anyone have any similar experiences? Last edited by glider : 08-23-2008 at 01:17 PM. Reason: merged

08-23-2008, 01:18 PM	#5 (permalink)
glider Community Liaison Ride: 07 Road King Classic Join Date: 2007, Jun 21 Posts: 10,389 My Mood:	re: Engine Dies And Runs In Spurts It's not necessarily at half tank, it's just that it is easier to locate at half a tank due to the gushing of fuel sound with the cap off.

08-24-2008, 09:01 AM	#6 (permalink)
hdrick01 New Family Ride: 2001 Fatboy Join Date: 2008, Aug 22 Posts: 4 My Mood:	re: Engine Dies And Runs In Spurts I have the same problem with my 01 fatboy FI. How do you replace the line? hdrick01

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08-24-2008, 09:04 AM	#7 (permalink)
glider Community Liaison Ride: 07 Road King Classic Join Date: 2007, Jun 21 Posts: 10,389 My Mood:	re: Engine Dies And Runs In Spurts It comes out through the top plate on the tank. Replace the gasket AND the bolts that hold the cover, they have a sealant on them.

08-24-2008, 09:13 AM	#8 (permalink)
hdrick01 New Family Ride: 2001 Fatboy Join Date: 2008, Aug 22 Posts: 4 My Mood:	re: Engine Dies And Runs In Spurts Thanks for the quick response, glider. I'll take a wack at it today. hdrick01

09-28-2008, 05:03 PM	#9 (permalink)
hdrick01 New Family Ride: 2001 Fatboy Join Date: 2008, Aug 22 Posts: 4 My Mood:	re: Engine Dies And Runs In Spurts I have a 01 fatboy. I followed Glider's instructions and boy what I found. 1) The line from the fuel pump to the fuel filter was fine, but the line from the petcock to the fuel regulator had 3 pin holes in it. 2) The tank liner inside the tank had cracked and pieces of the lining were all inside the tank. So, when replacing the line (lines) be sure to replace the filter. When purchasing the filter the line comes with it (fuel line kit) When replacing petcock line the petcock comes with it (kit). It's a relatively simple job, just follow instructions (ask dealer for interior tank parts pic and parts numbers) if you don't have a repair manual. Hope helps anyone that has the same problems. Thanks again to you Glider HDRick01

09-28-2008, 05:07 PM	#10 (permalink)
glider Community Liaison Ride: 07 Road King Classic Join Date: 2007, Jun 21 Posts: 10,389 My Mood:	re: Engine Dies And Runs In Spurts Glad it helped you out.

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Engine Dies And Runs In Spurts

Diagnostics and Fuel Injection Related