2000 Black bird main harness failure and coil design misfire
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  1. #1

    Member #
    2343
    Bike(s)
    2K Titanium, 85 V65 Sabre (Totalled but saved me)
    Join Date
    Sep 24 2007
    Location
    Arizona
    Posts
    7,060
    Liked
    1819 times

    2000 Black bird main harness failure and coil design misfire

    Hello gents
    After a lot of checking head scratching, testing, head scratching theorizing and more testing and head scratching I have finally got this darn thing happy. Fist issue/ fault was some where in the main harness between the CKP (crank position sensor) CPS (cam position sensor) and the ECU. It created a intermittent missfire. When analyzing the AFR I would see a shift from 13.8 which is where I tune to almost 18 to 19 then back to 13.8. When this happened the bike would drop cylinders. Flexing the harness near the ECU at the 180 bends would cause the drop. The bike also had a helacious cam drive noise (buzzed like hell) I made a video of the sound and posted pics. The harness actually gave up the ghost during testing after the video. It opened up and killed the signals completely to the ECU and of course the bike ceased to run. Fast forward to new harness install and bike came back to life but still had the stutter. Well tonight I went back at it again this time looking at firing timing. When the bike was fired it would run with the stumble and number 1 and 2 cylinders head pipes had about 100 to 150 degrees difference to 3 and 4. Now the plugs are fired in this fashion. As your setting on the bike the right side coil controls 1 and 4 the left 2 and 3. so the thought that one coil was iffy goes out the window because the the cold cylinders were on each coil set. So luckily I have a spare engine here with nearly zero miles. So I swapped out coils and walla, eureka, alleluia the misfire is gone. Attached are links to 2 videos one before with the existing coils and then with the correct factory coils installed.

    https://youtu.be/SwLvjhI0Mbo

    https://youtu.be/kH78f5lb0-E
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

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