2007 EFI 4K RPM Ignition Miss Problem

[BigDogBro1]

Hi Guys,

Have a 2007 EFI bike that has an ignition misfire or interruption at 4000 RPM pretty consistantly. If you roll up easy on the throttle or crank on it, it will start to miss at 4000 RPM. It runs perfectly fine under 4000 RPM and won't seem to exceed 4000 RPM by much once it begins to misfire.

S&S is quite sure it's not the EFI box reset back to break-in RPM limit.

So far installed new:
Crank sensor
Ignition coils and plug wires
Spark Plugs

Have an idea what other possibilities it could be but want to hear some other ideas as to what it could be.

Help me Sven, please!

 

[erldawg]

Hi Guys,

Have a 2007 EFI bike that has an ignition misfire or interruption at 4000 RPM pretty consistantly. If you roll up easy on the throttle or crank on it, it will start to miss at 4000 RPM. It runs perfectly fine under 4000 RPM and won't seem to exceed 4000 RPM by much once it begins to misfire.

S&S is quite sure it's not the EFI box reset back to break-in RPM limit.

So far installed new:
Crank sensor
Ignition coils and plug wires

Have an idea what other possibilities it could be but want to hear some other ideas as to what it could be.

Help me Sven, please!

Did you connect up a computer to verify rev limits?

Change the plugs?

I know mine sputters a bit before it's fully warmed up. I thought I had over come the issue but has returned. I'm really not to concerned as after it's warm runs like there's no tomorrow.

I could send you my removed EFI module for you to plug in and try.

 

[BigDogBro1]

Don't think the REV limit is viewable or changable in the Protune2 software. The EFI module is factory locked......

I added spark plugs to the list above as well.

Thanks for the EFI module test offer!!! I have a few things to check with Protune2 before any teardown attempt.

 

[erldawg]

Don't think the REV limit is viewable or changable in the Protune2 software. The EFI module is factory locked......

I added spark plugs to the list above as well.

Thanks for the offer!!! I have a few things to check with Protune2 before any teardown attempt.

Any DTC error codes?

 

[ChoppaNoob]

Could be a simple as a lose connection or ground somewhere. As the rpms go up so does vibration and things start to rattle. I had this problem on my sportbike once and it turned out to be the kickstand switch rattling.

 

[BigDogBro1]

No DTC last time I checked. Will be connecting up the laptop soon for another look see.

Vibration? Yes...that's where I'm headed for the next wave of diag tests. I will be checking the TPS for irratic feedback at 4000 RPM via Protune2 sensors view.

Update:
Seems that if the throttle is backed off and hit again the engine will rev past 4k RPM. Could indicate vibration caused problem.

 

[pknowles]

Damn, another problem to look forward too. keep us posted when you find the problem/fix.

 

[agourabob]

I posted this today about a 2007 Buldog's EFI problem. See below


I have been troubleshooting a Bulldog that quits when hot. We spent considerable time on it yesterday and determined that temperature (330) was shutting down the EFI computer and when we cooled down the sensor it would start again. The question was, is it the sensor or is it running too hot.

I called S&S today, they were great. The tech support person I spoke too thought that 330 would be the limit on temperature for this engine. He felt the existing non programmable EFI module was causing the bike to run too lean (EPA) and is not re programmable.

They sell an off road module replacement and have a bunch of them. They retail for $355 and come programmed for BD engines, I believe plug and play.

The data below is subject to confirmation, but the module number for the 07 EFI bulldog is 55-50-29. Only sold by S&S dealers, not the factory and should be plug and play. I would think this is an extremely valuable asset for this bike and should be kept in mind while they are available.

Hope this helps more guys with similar problems.

Bob

 

[erldawg]

I posted this today about a 2007 Buldog's EFI problem. See below


I have been troubleshooting a Bulldog that quits when hot. We spent considerable time on it yesterday and determined that temperature (330) was shutting down the EFI computer and when we cooled down the sensor it would start again. The question was, is it the sensor or is it running too hot.

I called S&S today, they were great. The tech support person I spoke too thought that 330 would be the limit on temperature for this engine. He felt the existing non programmable EFI module was causing the bike to run too lean (EPA) and is not re programmable.

They sell an off road module replacement and have a bunch of them. They retail for $355 and come programmed for BD engines, I believe plug and play.

The data below is subject to confirmation, but the module number for the 07 EFI bulldog is 55-50-29. Only sold by S&S dealers, not the factory and should be plug and play. I would think this is an extremely valuable asset for this bike and should be kept in mind while they are available.

Hope this helps more guys with similar problems.

Bob

Good price did you purchase one?

 

[BigDogBro1]

Thanks for the info Bob. Did all the research with S&S a year ago on the locked ECU but they feel it's the TPS at this point. I haven't got back to the bike for further testing. It does run fine up to 4k RPM.

 

[BigDogBro1]

Hi Everyone,

UPDATE 7/22/13: Intermittent 4000 RPM engine misfire (Rev limiter effect). 2007 EFI Bulldog

Once in awhile the bike would roll through the 4000RPM misfire point and run strong and then next time you try it later, the engine would misfire.

Had the time to do a data capture during a 5 minute test ride. Connected a notebook PC to the S&S USB port while running S&S Protune2 gauge screen. Captured the desktop screen video using CamStudio and went for a quick ride. The results showed no obvious problems and lead to a dead end. S&S couldn't see anything either nor could they come up with any NEW ideas that we hadn't already tried as a fix. Wanted to test the fuel rail pressure (58-62psi) but due to hot and humid days we never got to it last week.

Bigdogbro2 wanted to ride Sunday so he was checking and cleaning his bike on the lift. He found the front spoiler and voltage regulator was about to fall off. We began to dissassemble the spoiler, bracket and regulator and found one bolt missing and the other half unscrewed for the two regulator mounting bolts. After cleaning everything, getting new bolts and lockwashers we reassembled the parts.

As a result of the NOW tight VR with a reliable charging ground connection the bike runs perfectly without any 4000 RPM misfire problem.
The VR is only GROUNDED thru the case. There are no wire grounds from the VR. Some aftermarket VR's have a seperate VR CASE ground wire but ours do not.

Here's my thoughts:
We have been messing with this ignition misfire problem for two riding seasons. I suspect that VR had loosened enough two years ago to allow an intermittent charging ground and while riding the VR would sometimes charge the battery enough the keep the bike running. Other times the battery voltage was low and caused this misfire condition. The bike always seemed to start just fine.

I plan on running a seperate 10awg GROUND wire from one of the VR mounting bolts to the battery ground point on the frame to enhance the VR frame connection ground on both our bikes. There are two external star washers used on the spoiler bracket to the frame mount bosses to help make a frame connection but I don't like the way the ground from the VR to the painted bracket is expected to allow a good ground thru the paint.

Anyways...I wanted to let you all know what I feel could have caused this misfire problem. Crazy as it seems I wanted to give some feedback on the possible fix.

UPDATE 8/12/14:
Another 150 miles over the weekend on Sunday without a problem. Seems it's fixed!

Enjoy the ride!

 

[pknowles]

Good to hear you got the problem fixed. These things are fickle.

 

[Slider]

Good find thanks