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Old 12-01-2012, 01:52 PM   #1 (permalink)
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04 dog sputtering / coil wire

Hi I recently purchased a big dog.
I have seen some similar topics but no fixes,
The problems I am.having is
1. Bike will miss / sputter at higher rpm and then run like crap, at the same.time the tach lights will flash n try to go off. " "happens when you give it full throttle "".
Bike runs and starts fine at low rpm

2. After this issue happens. The plug wire pops off the coil and then runs like crap and dies . I then have to take.cover off and put wire back on.
I open the gap size on the hole hoping it was just loose but same.issue comes up.
I dropped it at a shop and he said it popped off on him to.
thing is I switched the wires and forgot to ask.him what wire fell off.
I was trying to see if one side of the coil was bad or Maybe a wire.
shop is closed and bike still there. He said maybe electrical or something with tachometer.
I hope I explained this enough to get any answers that will.help my problem
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Old 12-01-2012, 02:56 PM   #2 (permalink)
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if the wire keeps popping off, try to find a way to hold it in place with a plastic wire tie and see if that helps any. try cheap first.
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Old 12-01-2012, 03:01 PM   #3 (permalink)
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The thing is. Only pops off when high rpm and full throttle not normal riding.
there's got to be a reason for this coil.wires usually just don't.pop off. Lol
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Old 12-01-2012, 03:52 PM   #4 (permalink)
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I have a zip-tie around the boot on mine too prevent them from coming off. also die-electric grease and heat shrink all connections. these things vibrate and it could be loosing a connection at high rpm.
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Old 12-01-2012, 04:04 PM   #5 (permalink)
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I had an 03 chop that liked vibrating one of the plug wires off. Butcher has it right. Wipe off the coil and the inside of the plug wire with alcohol. Push the cap on and zip tie it. Solved the issue on my 03.
Explain "High RPM"
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Last edited by KaptinAmerika; 12-01-2012 at 07:46 PM.
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Old 12-01-2012, 04:58 PM   #6 (permalink)
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If the plug wire pops off the coil I hope it runs like crap

Might be worth while to get a new set of plug wires, not sure what you got but its generally just a thin piece of metail in there and it could just be stretched out allowing the plug wire to pop off easier than it should. It has happened to me once before.
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Old 12-01-2012, 07:21 PM   #7 (permalink)
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Ill try this next week after the bike comes back,

But it will only pop off after higher rpm driving, so my question is when I hit say 4000 rpm. And it starts to sputter, but doesn't fall off would this miss be caused by maybe the wire moving? Or loose?
I have seen some wires that are barely on. Bike runs fine until it falls off.
my bike sputters only high rpm even with wire on tight as far as I can feel ..


Ill try all this and hope.forbthe best. Thanks
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Old 12-01-2012, 10:32 PM   #8 (permalink)
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could take a pair of pliers and squeeze the wire end a little so it is harder to get on/off and thereby make better contact but i would still try the wire tie. logic only tells us that the more rpm something is turning the more vibration it is going to create.
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Old 12-02-2012, 03:46 AM   #9 (permalink)
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If tha motor is missin out at 4000+ and then the wire is comin loose. That sounds like the wire is your problem. Might do as the others have said and zip tie the wire in place.
Also would be good to check all your motor mounts to be sure everything is tight and know excesive vibrating is cuasing the wire to come loose.
If you zip ite it and everything works I would get a new set of wires and tie them as mentioned. You can fix this with out payin the shop to do it.
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Old 12-03-2012, 07:47 PM   #10 (permalink)
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Well I picked up the bike. But the roads are wet.
I opened the coil wire some and then zip tie wouldn't stay good so I used some.black 2 sided goo adhesive stuff,I got on it a few times and it dermatology be better and missing is less its hard to tell with wet roads. But I do feel the difference! !! I hope this is the main issue and.ill add some more adhesive tape.
Now I noticed another issue ill post here and as well open a new topic. If no answers

My tachometer / speedometer has rpm lights. Some yellow green and red. Well they are all flashing like a Xmas tree when I drive n then stop .
if I'm at a light and rev it up the lights go away and just show the rpm light
but once I drive it again all the lights go crazy,
Any one know a fix for this?
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Old 12-03-2012, 08:33 PM   #11 (permalink)
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Idol is set to low.. anything under 1000rpms it will flash..
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Old 12-03-2012, 09:24 PM   #12 (permalink)
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Quote:
Originally Posted by Slick-Dog View Post
Idol is set to low.. anything under 1000rpms it will flash..
thanks
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Old 12-03-2012, 10:46 PM   #13 (permalink)
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Get your problem solved ???
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Old 12-04-2012, 05:29 PM   #14 (permalink)
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Ill find out soon. Its been raining. To try it out. Ill fix idle as well Thursday.

Ill get back to you
Thanks
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Old 05-04-2013, 03:18 PM   #15 (permalink)
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Well problem has been temp. Fixed.

Using tar tape and zip tie did work. Problem is high rpm vibration causes coil wire to pop off. No bigger issue , bike runs strong now. Not sure if coil is bad but
I think ill try a new or different coil to see if i dont need all this extra help .

So thanks for the help . And for other readers now they know the answer
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