Occasionaly runs like crap.

[SizemattersIII]

Mr. RocketEd , I maybe outside the box here but, possible just because the headlight mod has been done doenst mean the ignition switch cant start giving you fits. mine started to act weird, so I did the Relay for the starter relay mod per Mr DeCosse's diagram found on Starter Relay mod by Mr. MitchPC. No more issues. Also check all grounds (prep and re-terminate if necessary). Those can make a ghost out of electrical issues. Check for wire chafing also.

 

[RocketEd]

Thanks for the feedback, I'm finally at the point I can spend some more time troubleshooting. (I thought retirement was supposed to mean more free time? ).
I've been over the bike a few times looking for chafed wires, but haven't checked all the way to the key switch. Grounds have been cleaned and retightened.

 

[pjsmithres]

My two cents.

A buddy rider had a similar but not exactly same problem on the road three years ago.

After a push (for a mile) to a Triumph dealer. Not the unlucky tow from the desert.

The dealer found a fuel line inside the tank on the fuel pump that had a crack in it and it blew/sucked air when the tank got below about 2/3 full.

Just saying, it might be a good idea that a check of the complete fuel system. Have to drain the tank and remove tank and remove the fuel pump and re=insert after check. It was a crack barely visible to the eye. only seen after they drained half the tank and looked inside the tank and saw the fuel pump spurting fuel into the tank. The fuel pump pressure was enough to blow out the fuel line.

Just a possible option to who seems like a mechanical effort is not that hard.

Good luck.
Repair and trouble shooting t dealer was about 6 hours.

 

[RocketEd]

Thank you for the feedback, it will be added to the list. I should probably yank/replace the fuel filter anyway.

Thing is, the bike starts and runs great 99.9% of the time. Hopefully be able to get back out on it tomorrow if the rain stops and the forest fire smoke isn't too bad.

 

[RocketEd]

Got in a couple hundred miles today and the Rocket started 4 times and ran great. On the 5th it pulled its bull**** again even though the fan hadn't kicked on. Starts right up, then shortly runs like crap when I try to accelerate. ALL the idiot lights come on, the neutral light stayed on, fuel gauge zeroed, 35mph top speed. Pull over and turn it off. Cycled the key a couple times, and nothing, no gauge sweep, etc.
Pull the main fuse, which looked fine, but stuck another in there anyway. Turn the key on and the gauges sweep and after a couple seconds the fuel pump primes, start it up and it runs great all the way home.
I thought the difference might be that I'd turned it off by putting the kickstand down with the bike in gear. Tried recreating the kickstand scenario a couple times on the way home, and no dice. When I got home I let it run till the fan kicked on, turned it off and waited a while before starting it again. Ran fine on the road test.
TuneECU showed a stored code PO560 ECM Power Supply, Circuit Malfunction. So now I'm thinking/hoping it's the ECM relay.
Going to have to rename this thing The Mystery Machine.

 

[RocketEd]

Looks like the relay fixed it. Rode it yesterday in 85 degree heat, including a mile of stop and go. Even gave it the ultimate chance to screw up - fan running, kickstand down to kill it in the Harley shop parking lot, so I'm calling it fixed. Don't know why I screwed around with all the other BS, it's always the relay. I just changed out the fan relay because it was blowing fuses.
I'm going to try and find an electronic relay to replace the Echlin AR272 - they just don't last on this bike.

 

[RocketEd]

Ok, so maybe it wasn't just the relay. Riding along yesterday at 50mph I noticed that a couple times the speedo would drop to ~20 and then go back to 50.
Stopped at a dispensary and when it was restarted the idle was rough, the turn signals blinked at seizure speed, the neutral light came on going down the road and the ABS light came on. Riding along at ~60 the gear indicator and turn signals went back to normal, but the ABS light stayed on. Stop at a light and the turn signals go back to seizure speed.
Made another errand stop and the bike's still acting up.
Stop for lunch and everything is perfect on restart.
Stop for gas and it's screwed again.
Stop the bike 10 miles later, turn it off for maybe 10 seconds, restart and everything's fine again.
The one major difference since replacing the relay is that other than the rough idle the bike runs really well while all the other BS is going on.
Bad ignition switch? Loose connections? Helifino.

Edited to add: I'm thinking it's time to redo my testing of the regulator and stator, since the rough idle and seizure speed turn signals at idle speed might be due to low power.
The battery has a resting 12.5 volts and passed a load test.
Pisses me off, I'd hoped to use the Rocket for my fall tour.

 

[atomsplitter]

Have you checked the ignition switch barrel contacts?

 

[RocketEd]

I have not. My checking of the switch has been limited to wiggling the wires and key and working a lot of cleaner through it (which made no difference). Can the ignition switch itself be taken apart once it's removed?

I started it several times in the garage earlier this week. 5 or more times it was fine, the next time it had the rough idle and frantic blinkers. Wiggling every wire I could get to, pounding bare handed on several parts of the bike and wiggling the key made no difference.

It may be a while before I get back to it unfortunately, since I've got a contractor to deal with and would like to take off for a week or so before the weather turns to complete crap.