My crazy buellster project... please help

[jbernstein]

Hello, I'm new to the forum and am pretty much out of places to turn for help. I'll start with some background. I decided to build a sportster with a s3 thunderbolt motor. I bought a wrecked buell and a sporster frame and went crazy. I got it done about the end of last summer and it ran great! scary fast (for me anyway) Against all advice I am desperately trying to keep the fuel injection that came on the s3 but recently it just started running like crap and I am pretty lost as to what could be the problem. I'm pretty sure there was no problem in the build because it ran great for about 6 months I'm pretty mechanical and very familiar with harleys but never had a fuel injected bike. It will idle beautifuly but the minute it's in gear it starts to missfire bad. It is running very rich and actually puffs black smoke with each exhaust. I thought fuel injection was supposed to fix itself in that area. I have replaced the o2 sensor and the tps. I have tried messing with the timing, but that only seems to make it worse. the dealer wants nothing to do with it and there is no diagnostic port on this bike to try to plug into. I am not sure if it ever had one as I am not the original owner of the wrecked buell but there are no extra pins in the ecm that could even output to a diagnostic port. could someone explain to me the diagnostic port and how the stuff works? maybe a wiring diagram or something that could show me where it might have been? I never saw one on the buell, but it was missing alot of parts. Any advice on what to try next would be very appreciated. Thanks in advance
Jay

 

[jbernstein]

 

[batman6669]

It could be the injectors. fairly simple and cheap to replace.

 

[nativeXb12Rbuell]

What year is the BUELL S3 engine??

google is great help to find info and pic .. you may also want to find a service manual (you can get them on ebay & several diferent Buell venders & maybe find a freebie to download )for a S3 of that year to help you trouble shoot the problem(s). it wil have all the info and pics of the ECM and diagnostic port and search for ECMspy and it is how you can get into the fuell/timing maps etc.. with the ecmspy cable there are several websites & threads here that show you how to build the cable or you can buy one on ebay with a cd with the ECMSpy program and lots of maps for different years.

see links below for parts and links to the threads you seek ....
150-Helpful-Links-for-Buellers....and-Growing.
Buell-Clothing--Parts-List---Foreign--Domestic
pegasusraceteam.com racewear
EBR racing team Donate Page support crew
Erik Buell Racing .com
Erik Buell & EBR gear & merchandise
Erik Buell Racing team & Geoff May..BuellXB thread
...make sure you fill out profile
PERSONAL-PROFILES
and dont forget to put yourself on the Buell Map
New-Google-Map-for-Buellers


also you said you replaced the O2 sensor , how is the wiring and you replaced the TPS do you mean the cable assembly or the sensor itself ?? what modifications or add ons did put on right before your problem started?? when you replaced the tps HOW did you reset it all back to proper specs ??

here is an easy way to find if there is any trouble codes to help narrow it down some,.. http://www.bcrider.com/DDFI.html or http://www.americansportbike.com/shoponline/ccp0-prodshow/9016.html

 

[jbernstein]

My donor buell was a 2000 s3t.

I just ordered a manual. should be here soon. I spent hours on google last night. that's how I found this site. I learned all about the ecmspy cable, however I don't have anything to plug it into. I replaced the o2 sensor because it was badly fouled from running so rich. The wiring is fine, was completely redone in the build. I replaced the sensor itself, but don't know how to bring it back to factory specs as I can't "plug in" to the bike. Do I need to reset anything because the sensor was new from the dealer. I've done no mods or add-ons and infact changed nothing since the build until the problem started.

batman, It could definetely be the injectors, but I'm trying to avoid replacing parts "blind" like I have been doing and am looking more to figure out how to get a diagnostic port on the bike or find someway to actually diagnose fuel injection problems, now and in the future

Thanks guys