Fuel Injector Harness Connector

Energy One
BigDogBro1

BigDogBro1

Made in the USA
2007 Bulldog EFI harness connector to fuel injector.

After helping Tom (Groundpounder) get his bike running I (Rob) and Tom spent ten hours over the weekend troubleshooting a rear cylinder dropout on my bike that has been getting worse over the last two years.
The first startup this spring (2016) since I had the front cylinder off to replace the base gasket. It would not idle and not fire consistently on the rear cylinder. Did a sparkplug test and was good. Although you could see the injector working during an engine crank with the plugs removed it was still this connection. After going thru swapping the coil, ECM and rear injector I decided it had to be a wire or a connector. Upon testing the wires from this connector back to the ECM I discovered that the tiny probe pin I was using fit snug in the 12v housing pin and VERY loose in the signal pin in this injector connector. Ah HA!!!!! I think I found it. So after a quick assembly to get a startup I tried pushing on the FI connector and sure enough it contacted good enough to get the bike to idle normally.

Here is information on the Keihin injector connector and how it may come apart to fix the pin.

http://www.bmotorsports.com/shop/product_info.php/products_id/2195 (I ordered from here) Cycle Terminal never returned my email.

http://www.cycleterminal.com/fuel-injector-connectors.html
Honda NH-1 , Suzuki


This video shows how this connector may be taken apart to get the pins out for replacement or in my case for bending the pin back for better contact. I think you remove the BLUE cover to gain access to the pin contact lock tabs to remove the wire.
How to Assemble:
http://www.connectorsfast.com/videos/X12.HONDA.FEMALE..mpg
 
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BigDogBro1

BigDogBro1

Made in the USA
Simple fix with ten hours labor and fortunately diagnostic parts available. The actual repair cost is ZERO. Will be glad to be on the road.

Have a great safe season!

UPDATE 4/19/16

Well not so lucky. The problem still persist. Swapped the F & R injectors and the misfire is now on the front cylinder. Could be a bad injector, so Tom is bringing over a NEW injector to try. I have a feeling I may have a weak original fuel pump and will test pump pressure soon. The engine idles fairly well for a few seconds then drops off.

UPDATE 4/20/16
Well back at it again. After work Tom brought over two new injectors and a fuel pressure testing kit. We connected the computer to the ECM and checked the temp sensor and the Bank Angle Sensor to be TRIPPED, all was fine. We tested the fuel rail pressure and get 55 psi. on initial pump up when you press RUN. Running is around 50 psi. and when the engine is turned OFF the pressure will slooowly drop to about 40 psi. So this means the pump is old and the regulator or an O-ring is leaking back. The pump however is in good enough shape to get another season out of it. I will replace it this winter.

I decided to replace both injectors with the two new ones Tom brought over. I was tired of messing with it even though I knew that only the one NOW front cylinder injector was a problem. After the injectors were installed we did a test START and the engine seemed to idle just fine and would REV up on a throttle twist. All seems to be working as normal now with GOOD injectors.

Cost to repair: Two fuel injectors (my choice), FI harness connector $12.00 shipped. ~17hrs.

Without having parts to try this diagnosis would have been nearly impossible...Thanks Tom!

Now Let's Ride!
 
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BigDogBro1

BigDogBro1

Made in the USA
UPDATE 4/25/16

Rode Saturday and when I got the bike on the road I had a cylinder miss. After the bike warmed up it ran better. By mid-day it was running better. The miss seems to happen when the engine is coasting with NO load. Got an engine check light on Saturday. "Bad front sites" so I merged the fuel maps and rode again on Sunday. Ran bad with a miss on and off. Seemed to clear a bit under power. Would happen occasionally during the day and got another engine light ON again. Need to check EFI box for code, spark plugs and O2 sensors. Still working thru it.

UPDATE 4/28/16
Bad REAR sites this time. Tested the O2 sensor heater elements and both are good. Further investigation reveals that the fuel pump may be at fault. Pressure at test was 50 to 54 psi static and 50 psi at idle. Needs to be near 60 psi. The engine gets a miss near 3000 rpm pretty much every time when early into the ride. This could be a symptom of fuel starvation under load or low fuel pressure. I will be replacing the 8 year old pump and regulator.
 
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Th3InfamousI

Th3InfamousI

Administrator
Staff member
Shit man! Thought you had this!

Am I reading that right 17 hrs to install the fuel injectors? It diagnostic and install, either way that's long time I'd be ripping my hair out.

Sent from my 831C using Tapatalk
 
BigDogBro1

BigDogBro1

Made in the USA
17 hours of troubleshooting and chasing the problem(s) and trying repairs. The injector was actually working but when flow tested it was only putting out 4 lbs/hr of fuel instead of 34.8 lbs/hr. So you can see the pain one can go thru working on a EFI system.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
BigDogBro1 said:
17 hours of troubleshooting and chasing the problem(s) and trying repairs. The injector was actually working but when flow tested it was only putting out 4 lbs/hr of fuel instead of 34.8 lbs/hr. So you can see the pain one can go thru working on a EFI system.
Click to expand...
Yep I would have been saying how much to go to a carb by now :)

Sent from my 831C using Tapatalk
 
BigDogBro1

BigDogBro1

Made in the USA
I will be replacing the fuel pump, regulator and tank filter as they are both original. 2007 Bulldog.
Walbro products sold by:
V.E. Petersen Co., Inc.
28101 E. Broadway
Walbridge, OH 43465

Fuel pump: #F20000107, Around $75
Regulator: #135-22 4bar/58psi, Around $41, and also get the two O-rings to install.
I think the in-tank fuel filter is the same as the Victory Cross Country 2003-2008.
It's the rectangular one with the hose nipple on it 2'-3" from one end on the flat side.
 
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BigDogBro1

BigDogBro1

Made in the USA
Update 6/9/16

Well I got the new fuel pump, regulator and O-rings, filter, access cover O-ring and fuel line all installed. Reloaded the unlocked base fuel map into the S&S ECM box and it's been learning and I have the check engine soon light come on but that was expected. Once I get more that the 20 miles that I have riden so far I will THEN merge the fuel map. The bike does have a misfire when run around 3000 RPM before it warms up but that may be the fuel mapping right now after a few minutes of running the bike runs just fine. I will continue to report back.
 
Jersey Big Mike

Jersey Big Mike

100K mile club
BigDogBro1 said:
Update 6/9/16

Well I got the new fuel pump, regulator and O-rings, filter, access cover O-ring and fuel line all installed. Reloaded the unlocked base fuel map into the S&S ECM box and it's been learning and I have the check engine soon light come on but that was expected. Once I get more that the 20 miles that I have riden so far I will THEN merge the fuel map. The bike does have a misfire when run around 3000 RPM before it warms up but that may be the fuel mapping right now after a few minutes of running the bike runs just fine. I will continue to report back.
Click to expand...
Do you have the part numbers and supplier for the Fuel Injectors.
I am having some similar trouble and might need to replace my injectors.
 
D

Dave67

New Member
Is the fuel screen at the fuel shut off at tank or at the car. Having a fuel problem on an 06 Mastiff. Hadn't been out for a few years. Think it might be rusty tank?
 
Brew

Brew

Troop Supporter
At the fuel shutoff inside the tank for carb models. By the way welcome to the site... :cheers:
 
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