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[woode]

Ever since my Fullsac upgrades (x-pipes, TTS, 1.75 baffles), I have had sporadic issues starting the bike. What happens is that it will crank for a few seconds, backfire, then smoke streams out of the air cleaner.  Please take a look at the below Youtube video to see what I am talking about.  Usually, it will start if I try again, but sometimes this happens a couple of times before it starts, as in the video.  I'm not saying that the upgrades caused the problem, but I did not have the problem before the upgrade.  I've gone back and forth between the dealer and Fullsac.  The dealer said that the ACRs were not enabled (they were), but they said that they enabled them and it took care of the problem.  Well, the problem remains, so I passed it back to Steve.  His response after watching the video:  "I watched the video. Backfiring through the intake is common when cranking RPM is slow. Its very obvious your engine is struggling to turn over.  Slow cranking can be caused by the ACRs being disabled and or low voltage to the starter, bad starter etc."  I sent an email to the dealer with a link to the video, and they never got back to me.

It's not that I disbelieve Steve, but you would think that the dealer would be able to troubleshoot this.  My warranty unfortunately expired last month, and I don't want to sink a ton of money in unnecessary service work while they try to figure it out.  Has anyone experienced this or have any suggestions?

Thanks,

Ed

[rheiner]

did you use Fullsac's map  together with your install? It sounds so because you got the TTS too. If so, maybe it has to do with that. I can't see the Fullsac pipe & baffles causing what you described. They are not that different than stock. If you did use his map, I presume you saved your original. Try reflashing the original back to your bike and see if your problem still happens.

[woode]

Yes, used their map.  When I discussed this with Fullsac, they gave me a slightly modified map to use, but it really did not make a difference.

Hey, it may have absolutely nothing to do with Fullsac, but it's a starting point.  No problems before I went down that path, so just trying to rule them out.

[Keats]

Do you keep the bike on a battery tender?  

This mostly happens on a "cold" engine?

Mine often does the same thing in a "cold" situation.

Happens more frequently with a "cold engine" and a slow rotation of engine.

I have to put the bike in "neutral" also.

I suspected my cam and higher compression did not help.

I doubt the the pipes have anything to do with the issue though.

I can tell by the starter noise if it will backfire.

advanced timing obviously makes it worse..............

[muddypaws]

Install a 2011 compensator.

[Fullsac Performance]

Yes, used their map.  When I discussed this with Fullsac, they gave me a slightly modified map to use, but it really did not make a difference.

Hey, it may have absolutely nothing to do with Fullsac, but it's a starting point.  No problems before I went down that path, so just trying to rule them out.

Ed
If you did not personaly do the down load and see the ACRs enabled, you may want to take matters in to your own hands.
Sorry to say, but I have delt with this situation more than once when paid mechanics
blundered the down load. Please verify it for your self. Its not that hard.

Steve

[steve-o]

My 08 has done the exact thing----off & on since new. Dealer checked battery/starter amps. Each time this problem flares up I end up with a new starter. Works perfect for 6-12 mos., then repeat. Service mangr. is good friend & says starters on 96s are the same as 110s. He says HD should make a heavier starters for the added compression. New Starter Works Every Time!!!  EXTENDED WARRANTY is paying off.

[woode]

Do you keep the bike on a battery tender?  When not in use for more than a week or so.
This mostly happens on a "cold" engine?  Usually, yes.
I have to put the bike in "neutral" also. Likewise

[woode]

Ed
If you did not personaly do the down load and see the ACRs enabled, you may want to take matters in to your own hands.
Sorry to say, but I have delt with this situation more than once when paid mechanics
blundered the down load. Please verify it for your self. Its not that hard.

Steve

Steve, I did the download myself after you explained the process to me a few months ago.  I know for a fact that the ACRs were enabled, so I was surprised when the dealer told me that they were not.  They told me that they enabled ACRs and that it took care of the problem, when in fact, it did not.  Further proof to me that they were wrong about ACRs in the first place.

I am by no means a mechanic, so I depend on the sage advice from you, members of this community, and when necessary, the dealer.  Your email to me regarding competency of  those performing work for me was certainly already on my mind, which is why I decided to elicit opinions from this knowledgeable group.

I truly appreciate your patience with me as I try to get this thing resolved.

Ed

[woode]

My 08 has done the exact thing----off & on since new. Dealer checked battery/starter amps. Each time this problem flares up I end up with a new starter. Works perfect for 6-12 mos., then repeat. Service mangr. is good friend & says starters on 96s are the same as 110s. He says HD should make a heavier starters for the added compression. New Starter Works Every Time!!!  EXTENDED WARRANTY is paying off.

I chose not to get the extended warranty, but I was dealing with this issue at least 4 months before the warranty expired.  If it is the starter, maybe the Dealer can get HD to pay for repair!

Thanks everyone for your comments and suggestions.

[woode]

Install a 2011 compensator.

So, now I will really show my ignorance...

What is a compensator, and what is the difference between mine and a 2011 version?

[Keats]

So, now I will really show my ignorance...

What is a compensator, and what is the difference between mine and a 2011 version?

A compensator is part of the primary which transfers power from the output shaft to the drive (belt).
I think it's main purpose is to eliminate vibration impulses and aberrations to the drive line.

I am not sure how a compensator would help in this situation...............

[Fullsac Performance]

Hey Ed

Just to be sure the ACRs are actually working, Can you take a compression test with a screw in gauge?
Cranking presure should be in the 125-150 range with the ACRs working. Around 180+ if not. This test will tell us a lot.

Steve

[sadunbar]

A compensator is part of the primary which transfers power from the output shaft to the drive (belt).
I think it's main purpose is to eliminate vibration impulses and aberrations to the drive line.

I am not sure how a compensator would help in this situation...............

A worn and loose compensator (loose meaning the compensator spring tension) can cause the motor to be out of time when starting.  A worn stock compensator could cause this issue.

[sadunbar]

So, now I will really show my ignorance...

What is a compensator, and what is the difference between mine and a 2011 version?

What year is your bike?  A 2011 bike comes with a SE compensator.  Earlier bikes came with the stock compensator.  A SE compensator has 7x more spring pressure.