Engine Stumble

[03HD883R]

I've got an '03 883R, and the only thing ignition wise that I've replaced were the plugs, the coil and the wires which I put on last year at ~65k. It's got about 77k on it now, and I noticed that I've been getting a stumble when riding. It only happens once, which is strange, but this time it was when I was making a turn. So I am kind of worried about it.

However, it has done it just cruising down the road, almost like it gets no spark for 1 second. Then it will not do it again, until I go through a whole warm up cycle. Which is quite frustrating to try to figure it out.

From my technical expertise and resources, it sounds like my ignition system is going. Anyone agree/disagree and/or elaborate?

A friend told me it might also be the Bank Angle Sensor... but I thought I'd lose it all the way and need to restart the bike as a safety precaution?

I've looked all over for chaffed wires, loose connections, corrosion, etc. All seems well.

Other than that, the bikes runs fine, just like the day I bought it.

 

[dbmg]

First be sure battery cables are clean and tight on both ends....Then check by performing a slight water mist to plugs and wires and see if you can duplicate complaint. Did you use factory HD plugs and wires of after market????

 

[03ultra45385]

Does there seem to be any relation to the engine RPM's and the stumbling?

 

[03HD883R]

First be sure battery cables are clean and tight on both ends....Then check by performing a slight water mist to plugs and wires and see if you can duplicate complaint. Did you use factory HD plugs and wires of after market????

I put a brand new HD AGM battery in last summer and cleaned and tightened the terminals to HD specs.

I am using factory HD plugs and HD SE plug wires, which are practically brand new.

Mind you, this happened last year before I replaced the coil (Voodoo 3 ohm), the wires, and plugs this past winter. But it only happened once or twice, and I thought it was just bad gas.

I will try the water mist to the plugs and wires and see if it does it.

Although, it hasn't rained or got wet on the bike in about 2 weeks and its ridden as my daily driver all over the place.

Does there seem to be any relation to the engine RPM's and the stumbling?

Nope. Lucky for me I have the HD tach on it, and it has happened as low as 2,200 rpms all the way up to mid acceleration at 3,200 rpms. I don't usually ride the bike over 3,500 rpms unless I need to do a certain maneuver to get into a lane or catch up with traffic quick, which is rare where I live. So my bike usually only sees from 950 rpm to 3,000 rpms, and occasionally 3,500 rpms. I've never red lined it or come close to it. Have no need to frankly.

 

[Jack Klarich]

Check the screw on caps on the end of the plugs snap the wires back on til you hear an audible click:s

 

[03HD883R]

Check the screw on caps on the end of the plugs snap the wires back on til you hear an audible click:s

I checked that too when out in the shop. I've seen them do that, but they were on as tight as can be.

I went on a ride with a Windex bottle of water sprayed a mist at the wires, coil, and plugs. Didn't bother it a bit. I even did it out in the shop, no change. This ride it didn't do it. Went about 30 miles intermittently spraying it at all angles. People probably thought what the heck is this guy doing!? (If someone stopped and asked, I would've been like, "Hey, you didn't hear about the Harley manual water cooling option, part no. 8842049?")

Yet, I had to go to work to get something I forgot, and when I was cruising, it did it. I quickly pulled over and carefully looked at everything, and not a sign of water or issue.

I'm still quite adamant at leaning toward the ignition module. I was looking at prices of them, and they are relatively cheap if I stay with the OEM compatible. As I was reading about engine cutout, and stumbles, other people have mentioned the Harley brand ignition modules seem not to like heat versus the aftermarket ones. Does anyone know who makes the stock one in the '03? I'm sure it's rebranded to say Harley on it... but I'm curious if it's Siemens, Bosch, TRW, or one of them.

I was looking at the CompuFire Original Compu-Fire Ignition Module - 20100, but says I need a manual timing advance for it? I thought that what my VOES is for!?

Or this one:

Daytona Twin Tec VT-I V-Twin Electronic Ignition System - 1010

I've been reading reviews on them, and they both have great reviews, but I want to make sure it's just a swap and not "Johnny, we need to fab something up"... if you know what I mean.

 

[Jack Klarich]

Here is your syock module 21 32466-98 IGNITION MODULE, INTEGRATED SENSOR 1 258.83 232.95

 

[03HD883R]

Well, I replaced the Bank Angle Sensor, made no difference.

However, while I was looking at the vacuum lines, I noticed they were in rough/cracked shape, so I replaced them, and I got a new VOES just for the heck of it. This resolved the issue.

After I got the hoses off I tested them on my MightyVac and no loss of pressure. So I did the service manual test of the old VOES and it wasn't working properly. So all along it was the VOES that went bad. I notice that the bike idles like new and doesn't have the sudden stumble after it warms up. It must have slowly been going bad over time.

On the other note, I bought a Dynatek 2000i electronic ignition with the programming harness and I'm going to put that on today. Like it's going to give me any extra hp... just a novelty item I guess. I was going to return it, but I have a lot of spare time this weekend, so I figured why not. I'm going to tie it into the OEM harness, using the same pins that the factory one came with. So if I wanted to go back to stock, it's easy.

FTW the service manual with the colored wiring diagrams helps tremendously!

 

[03HD883R]

Oh, and people were telling me to chop up the wiring harness... and I looked at them funny. Ain't no way am I using unsealed spade connectors versus a sealed Deutsch connector.

I enjoy using my soldering iron and I've got a case of old Kester "#44" leaded flux cored solder... I find it rather relaxing.

 

[03HD883R]

Well, I installed the 2000i, and install went extremely smooth and the instructions were quite well written. I'm quite impressed as to how well it went in and I noticed it is a little more snappier (might be my imagination though).

Like I said, having that service manual is a Godsend with the colored wiring diagrams! I can easily see someone who doesn't have one or has never did electrical work on vehicles, can really fry something.

No more issues of stumbles that's for sure.

It's like having a new bike all over again.