Lightnin Lyle
Member
Looking for some advice. Here's what I know so far. Installed 99 TLEu sidecar on a 2000 Road King last week. Took it for a test ride around the block, tweaked the alignment, everything worked fine. Next day, took it on back roads to work and after 4 miles the engine just quit running, no sputter, no mechanical noise, just stopped dead in its tracks. Bike turned over but would not fire. Towed home.
I have been going through the bike and sidecar and talking to a few local dealers and here's what I know:
1) bike has spark, the fuel pump primes, but no fuel delivery to EFI
2) bike will start on first crank and run on starting fluid through the throttle body (MM EFI)
3) all fuses check out
4) speedo diagnostics show 3 DTC codes: 41 crankshaft sensor; 44 Bank Angle Sensor, and 56 crank/cam sensor signal error; the codes are current not historic; disconnecting battery doesn't clear the codes
5) pulled crank and cam sensors, no metal deposits on magnets
6) discovered a break in the black wire in the sidecar harness, when brakes were applied the brake lights worked on the bike, but not on the sidecar (all lights turned off), repaired wire and all running, tail and brake lights function normally, now (there is no bulb in the right turn signal on the bike per TSM spec)
7) I could just start replacing sensors, but it seems a little too coincidental that all three would fail simultaneously in the first run after the sidecar was installed
8) throwing sensors at the problem seems premature without knowing what actually caused the failure and tripped the DTCs and shut down down the fuel
9) this is a TSM config, not a TSSM, no security or rollover switch and the BAS is independent of the TSM and the ECM
10) local dealers are in disagreement about "resetting" the TSM/ECM to be configured for sidecar operation
11) when the run switch is cycled on and off, there is a "mechanical gurgling sound" in the region of the EFI throttle body, but no fuel is present after cranking
12) bike doesn't start with sidecar unattached, either
Is there something really obvious that I am missing here?
The Road King only has 6K miles on it and ran perfectly the last ten years.
Oil changed at 1200 mile intervals; HD synthetic everywhere
Should I start putting the multimeter on every electronic component in the chain, beginning with the crank, cam and BAS sensors?
Any help and suggestions in troubleshooting this issue before admitting defeat and towing it to a dealer is greatly appreciated.
Thanks.
Lightnin' Lyle
I have been going through the bike and sidecar and talking to a few local dealers and here's what I know:
1) bike has spark, the fuel pump primes, but no fuel delivery to EFI
2) bike will start on first crank and run on starting fluid through the throttle body (MM EFI)
3) all fuses check out
4) speedo diagnostics show 3 DTC codes: 41 crankshaft sensor; 44 Bank Angle Sensor, and 56 crank/cam sensor signal error; the codes are current not historic; disconnecting battery doesn't clear the codes
5) pulled crank and cam sensors, no metal deposits on magnets
6) discovered a break in the black wire in the sidecar harness, when brakes were applied the brake lights worked on the bike, but not on the sidecar (all lights turned off), repaired wire and all running, tail and brake lights function normally, now (there is no bulb in the right turn signal on the bike per TSM spec)
7) I could just start replacing sensors, but it seems a little too coincidental that all three would fail simultaneously in the first run after the sidecar was installed
8) throwing sensors at the problem seems premature without knowing what actually caused the failure and tripped the DTCs and shut down down the fuel
9) this is a TSM config, not a TSSM, no security or rollover switch and the BAS is independent of the TSM and the ECM
10) local dealers are in disagreement about "resetting" the TSM/ECM to be configured for sidecar operation
11) when the run switch is cycled on and off, there is a "mechanical gurgling sound" in the region of the EFI throttle body, but no fuel is present after cranking
12) bike doesn't start with sidecar unattached, either
Is there something really obvious that I am missing here?
The Road King only has 6K miles on it and ran perfectly the last ten years.
Oil changed at 1200 mile intervals; HD synthetic everywhere
Should I start putting the multimeter on every electronic component in the chain, beginning with the crank, cam and BAS sensors?
Any help and suggestions in troubleshooting this issue before admitting defeat and towing it to a dealer is greatly appreciated.
Thanks.
Lightnin' Lyle