Harley Problems

[Jeff Klarich]

Here a pic of the backing plate mounted to the engine. Note the 3 extended spacer bolts that the filter is mounted to.
Remapping may be in your future, with adding more air you'll want to think about a fuel management system. When adding more air you'll also be leaning it out, adding more fuel will balance it all out and as an added bonus your engine will run cooler.

 

[Jeff Klarich]

Take a look on eBay, lots of stage 1 setups for sale.

Arlen Ness Stage 1 Big Sucker Air Cleaner Harley 99-15 Twin Cam - Natural Plate (Fits: 2001 Harley-Davidson)

 

[fin_676]

If both the air cleaner and exhaust are less restrictive than stock then more fuel will be required to match the increased air flow

Brian

 

[J-Rod]

last night i pulled the air breather and started the motor to watch the butterfly operate when i ran thru the rpm's. The flap barley moved and was extremely sluggish. Not knowing if this was normal my buddy pulled his off of his bike and did the same process, there is a very big difference in the throttle body door opening and speed from mine. looking like this might be my problem im not sure if i need to replace the "servo motor for the throttle body or if i need to look for a relay?

 

[Jeff Klarich]

WITHOUT starting your scoot crack the throttle wide open, see if it opens completely. The butterfly should be open all the way, if not you need to adjust the throttle cable.
When you added the new bars and cables you may have not got the adjustment correct. If it's not opening completely start adjusting the cable while watching the butterfly until it fully opens.
Also make sure you have the snap back when you release the throttle grip.

Take a look here. :HowTo Adjust Harley Davidson Throttle Cables - YouTube

 

[J-Rod]

It's a throttle by wire there is no cable . I believe that the 2008 was the first year for the TBW and the 96 inch with a 6 speed Tran.

 

[Jeff Klarich]

It's a throttle by wire there is no cable . I believe that the 2008 was the first year for the TBW and the 96 inch with a 6 speed Tran.

I guess my bad, in post #124 you said you changed the bars and cable kit so I assumed you had cables.
I'm not familiar with the TBW so hopefully someone who is will chime in with their suggestions.

 

[J-Rod]

sorry for the miss lead on that but i do relay appreciate your advice. i seem to think its that control box on the side of the air intake. there is about 5-6 metal clips on it and looks like its molded for some small motors on the inside. Don't know if i should open it up or not lol.

 

[Jeff Klarich]

Read this and you can also type Throttle by wire in the search forum area and see if any of the problems and fixes may help you.

e by wire tech bulletin
Discussion in 'Diagnostics and Fuel Injection Related' started by Jack Klarich, Feb 2, 2014.

Watch Thread

1. 
   Jack KlarichExpert MemberContributor
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   TT418A service bulletin applies to 2008-Later Touring, Police & Trike Models
   
   Symptoms: Driveability or Performance Concerns; Abnormal or Erratic Mechanical Operation; Intermittent or Erratic Electrical Operation.
   
   Note: Throttle Position Sensor (TPS) circuit DTC's P0120, P0220, P0122, P0123, P0222 and P223 should take diagnostic priority over a P2135 code. If any of these TPS codes exist concurrently with the P2135, they should be investigated first using the diagnostic manual.
   
   The TCA has two potentiometers (designated as TPS1 & TPS2) and a electric DC motor for controlling the actuation of the throttle. The two TPS sensors work opposite of each other. As the throttle plate opens , TPS1 voltage ranges from 0.0-5.0 Volts, while TPS2 voltage ranges from 5.0-0.0 volts. The sum of the two TPS voltages should always measure approximately 5.0 volts. These wire are: TPS1, pin # 37 (BN/V wire) of the ECM, and TPS2 pin #36 (BN/R wire) of the ECM
   
   The TPS1 and TPS2 sensors should never add to more than 5.13 Volts Direct Current (VDC) or less than 4.87 VDC . A sum of voltages out of this range should register a current P2135 code.
   
   Troubleshooting:
   It is believed that FRETTING CORROSION is a major contributor of this code. A poor connection at the Throttle Control Actuator (TCA) can affect the sensor voltages reported to the ECM and this will set this DTC. As you can see from the General Information section, the sensor voltage only need to be altered by 0.13 VDC to possibly set the code.
   
   The most common vehicles to have these symptoms are those with more than 8,000 miles (12875 Kilometers) or 103 cubic inch and larger engines. Vibration is believed to contribute to the FRETTING CONDITION.
   
   Repair Procedure:
   1. While monitoring the TPS1 and TPS2 voltages on Digital Technician 2 (DT 2), wiggle the TCA [211] and the ECM [78] connectors.
   2. If the voltage changes while wiggling the ECM connector , replace the affected ECM terminals (part # 72605-08). These wires are: TPS1, pin #37 brown/violet wire of the ECM, and TPS2, pin #36 brown/red wire of the ECM.
   3. If no voltage change is noted while moving the ECM connector , the connection issue could be in the TCA. Replace all socket terminals with NEW terminals (part # 72663-11, used in current production) at the TCA connector[211B].
   4. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC GREASE.
   
   DTC P2101
   
   General Information: The TCA contains two potentiometers (designated as TPS1 & TPS2) and a electric DC motor for controlling a actuation of the throttle. TPS1 & TPS2 are mounted in the TCA. They are connected to the keyed shaft of the throttle plate and used to communicate the throttle plate position.
   Each TPS supplies input to the ECM in response to the position of the throttle plate. The ECM activates the motor in the TCA to move the throttle plate, based on signals from the Twist Grip Sensor (TGS). When the ECM send voltage modulations to pins 2 & 3 0f the TCA to move the throttle motor, it checks fo subsequent TPS1 and TPS2 voltage changes. If it does not sense TPS changes it will set this code.
   
   Troubleshooting: First verify that the throttle plate moves freely when engine is not running. If it does not the TCA needs to be replaced.
   Poor ECM connections seem to be the most likely cause. Be aware that this issue may be aggravated by the seat pan making contact with the ECM connector. In most cases, this is caused by the installation of an aftermarket seat.
   A poor connection at ECM pins #29 & 30 could cause an interruption in voltage to the throttle motor and set this code. Similarly the ECM uses voltage from pin #52 yellow/green wire to supply power used at pins #29 & 30 and could cause the same symptoms.
   
   Repair Procedure:
   
   Identifying the connection issues at this location may be difficult.
   1. Replace all socket terminals with NEW terminals (part #72663-11 used in current production) at the TCA connector [211B].
   2. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC GREASE

 

[Jack Klarich]

Pull off your right grip and try the throttle, the plastic gear on the end strips out easy