XR1200 idle and stall issues

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XR1200 idle and stall issues

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thefinalmasquerade
13 days ago

Hey folks, just bought a xr1200 that had been sitting for a while and it stalled refused to start even with a bump start. Engine was backfiring before and would stall on idle before this happened. I had put 98ron fuel in it the day before to get the RWC.

Called the shop that did the RWC and off it went to diagnose the issue, as this happenned while I was away from home. Now its been fixed with a bill of more then $2000 and still stalls itself when idling and backfires when dropping gears. Engine runs like its out of breath, which it didnt do earlier.

I am not sure if I got shafted with that bill but for it to not work afterwards is twice the pain. Fuel injectors, spark plugs and fuel pump (which was the issue) have all been fixed. Not sure what could be the issue with the bike, keen to hear your thoughts

Hilly
13 days ago

Hey mate, when you say it wouldn't turn over do you mean the engine wouldn't turn over or that it just wouldn't start?

thefinalmasquerade
13 days ago

Quoting Hilly on 09 Feb 2025 09:29 AM
Hey mate, when you say it wouldn't turn over do you mean the engine wouldn't turn over or that it just wouldn't start?

Thank you for your reply. It wouldn't start even with a bump start 2nd gear.

It starts now after $2300 service but stalls, backfires and runs like its out of breath.

Hilly
13 days ago

Cool so the engine was turning over just not starting, do you know what they replaced exactly? Spark plugs obviously but injectors? Were they replaced or cleaned? The fuel pump, was it the whole shebang or just the pump? There are a few things that cause issues like this. Could be electrical.
For what it's worth they should be fixing it after taking your money but do they know how would be my concern here as they were willing to let you take as it is and call it fixed.

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thefinalmasquerade
13 days ago

Quoting Hilly on 09 Feb 2025 11:45 AMedited: 09 Feb 2025 11:46 AM
Cool so the engine was turning over just not starting, do you know what they replaced exactly? Spark plugs obviously but injectors? Were they replaced or cleaned? The fuel pump, was it the whole shebang or just the pump? There are a few things that cause issues like this. Could be electrical.
For what it's worth they should be fixing it after taking your money but do they know how would be my concern here as they were willing to let you take as it is and call it fixed.

Cleaned injectors, replaced spark plugs and the bill (attached) states entire fuel assembly, regulator and fittings but I was showed only the fuel pump as replaced part.

Followed up with the mechanic and his response is defensive 'that this is what is expected when buying old bikes which hasn't been started in many years and that when you buy a Harley expect to pay for fixing them regularly as Harleys aren't Honda's'. And wants to do a compression test to check if the engine and valves are okay 'because for sure there are other problems with the bike'.

Not sure if I entirely trust anyone that throws new parts at problem before checking things like compression or battery before hand because in his words the bike has been sitting for a while, but proceeds ahead to flush the brake system.

More then half the things have been done without my consent and I dont feel confident in his abilities to fix the issue.

Hilly
13 days ago

For a bike that's been down awhile all those things they did would need doing, surprised the battery was still serviceable to be honest, the tyres could be iffy, what I'm saying is it looks like they did the things that would need doing although I disagree with their sentiment towards Harleys in general, your bike is a pup K's wise, sporties run for 200k easy if they are looked after.
But, none of that helps your current problem, I've not owned an injected sporty, do you know if it has been cammed or tuned?
I would start with seeing if it has thrown any codes since you got it back, do you know how to get them from the bike?

B0nes
12 days ago

Not sure if intake manifold seals were replaced but it sounds like my old Ultra. When I bought her she had been sitting for a while, intake seals were buggered from sitting for so long. Replaced those and she ran like a swiss watch. Plus I wouldn't be taking it back to that shop. Find somebody else if you can.

thefinalmasquerade
12 days ago

Quoting B0nes on 09 Feb 2025 10:26 PMedited: 09 Feb 2025 10:31 PM
Not sure if intake manifold seals were replaced but it sounds like my old Ultra. When I bought her she had been sitting for a while, intake seals were buggered from sitting for so long. Replaced those and she ran like a swiss watch. Plus I wouldn't be taking it back to that shop. Find somebody else if you can.

Thank you for your reply. Yeah, not going back to that shop for sure.

Will look into the intake manifold seals! Have also been recommended to check the Idle air control valve (IAC), as they do tend to clog up.

thefinalmasquerade
12 days ago

Quoting Hilly on 09 Feb 2025 12:11 PMedited: 09 Feb 2025 12:12 PM
For a bike that's been down awhile all those things they did would need doing, surprised the battery was still serviceable to be honest, the tyres could be iffy, what I'm saying is it looks like they did the things that would need doing although I disagree with their sentiment towards Harleys in general, your bike is a pup K's wise, sporties run for 200k easy if they are looked after.
But, none of that helps your current problem, I've not owned an injected sporty, do you know if it has been cammed or tuned?
I would start with seeing if it has thrown any codes since you got it back, do you know how to get them from the bike?

For all the parts that needed replacing, I would have expected a photo of the part or results of any testing e.g. battery test results, spark plugs etc. brake pads 1mm remaining, need replacement. To change things with no reapproval from me or provide cost as asked is just dodgy. It was from a deceased estate, so no idea if it was cammed or tuned unfortunately.

There were just two error codes - B1121-22 turn signals left and right (led) and U1016 Loss of ICM/ECM Serial Data Instruments. I cleared them and the turn signal codes came back but thats probably because of the led indicators.

I have had the battery professionally tested, no issues there at all. Looked at the relays/fuses and did an ohm test, they seem to be working alright.

My guess from reading on this bike, it could be the IAC or the fuel (98ron) I put in. Manual says 95, might be causing combustion issues as the mechanic noted - fouling sparkplugs.

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Hilly
12 days ago

I'm not defending them, there definitely should of been some consultation I'm just trying to make you feel a bit better about it.
IAC can cause issues for sure and it's easy to clean, other thing that might be a culprit is the crank sensor, they don't normally chuck a code but they can play havoc, a service manual is a pretty handy thing to have, you can get PDF ones online but I prefer a hard copy, easier in the shed.
You have a few things to check, see what you come up with.
To check the throttle body seals, with it running spray co cleaner or the like around the seal areas and see if it alters the idle.

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obisteve
12 days ago

Quoting Hilly on 09 Feb 2025 12:11 PMedited: 09 Feb 2025 12:12 PM
For a bike that's been down awhile all those things they did would need doing, surprised the battery was still serviceable to be honest, the tyres could be iffy, what I'm saying is it looks like they did the things that would need doing although I disagree with their sentiment towards Harleys in general, your bike is a pup K's wise, sporties run for 200k easy if they are looked after.
But, none of that helps your current problem, I've not owned an injected sporty, do you know if it has been cammed or tuned?
I would start with seeing if it has thrown any codes since you got it back, do you know how to get them from the bike?

Quoting thefinalmasquerade on 09 Feb 2025 10:50 PM
For all the parts that needed replacing, I would have expected a photo of the part or results of any testing e.g. battery test results, spark plugs etc. brake pads 1mm remaining, need replacement. To change things with no reapproval from me or provide cost as asked is just dodgy. It was from a deceased estate, so no idea if it was cammed or tuned unfortunately.

There were just two error codes - B1121-22 turn signals left and right (led) and U1016 Loss of ICM/ECM Serial Data Instruments. I cleared them and the turn signal codes came back but thats probably because of the led indicators.

I have had the battery professionally tested, no issues there at all. Looked at the relays/fuses and did an ohm test, they seem to be working alright.

My guess from reading on this bike, it could be the IAC or the fuel (98ron) I put in. Manual says 95, might be causing combustion issues as the mechanic noted - fouling sparkplugs.

Won't be the higher octane fuel in the short time you seem to have been running it. That can reputably cause plug fouling eventually but I've never had it. With the tiny tank you just pick different fuel next time you fill.

crowster69
12 days ago

my dyna is running about 10.2-1 comp and hates 98 fuel with backfiring and bogs down and just about stalls but loves the 95.I think a stock xr 1200 is running lower compression than that so id start with fuel.

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thefinalmasquerade
12 days ago

Quoting Hilly on 10 Feb 2025 01:50 AM
I'm not defending them, there definitely should of been some consultation I'm just trying to make you feel a bit better about it.
IAC can cause issues for sure and it's easy to clean, other thing that might be a culprit is the crank sensor, they don't normally chuck a code but they can play havoc, a service manual is a pretty handy thing to have, you can get PDF ones online but I prefer a hard copy, easier in the shed.
You have a few things to check, see what you come up with.
To check the throttle body seals, with it running spray co cleaner or the like around the seal areas and see if it alters the idle.

Totally understand your perspective and appreciate it!

Will be handling that next with fuel change to 95, hope that does the trick. Would you also recommend changing the TPS sensor while I am in there?

Have found the workshop manual, shouldnt be too much trouble.

thefinalmasquerade
12 days ago

Quoting Hilly on 09 Feb 2025 12:11 PMedited: 09 Feb 2025 12:12 PM
For a bike that's been down awhile all those things they did would need doing, surprised the battery was still serviceable to be honest, the tyres could be iffy, what I'm saying is it looks like they did the things that would need doing although I disagree with their sentiment towards Harleys in general, your bike is a pup K's wise, sporties run for 200k easy if they are looked after.
But, none of that helps your current problem, I've not owned an injected sporty, do you know if it has been cammed or tuned?
I would start with seeing if it has thrown any codes since you got it back, do you know how to get them from the bike?

Quoting thefinalmasquerade on 09 Feb 2025 10:50 PM
For all the parts that needed replacing, I would have expected a photo of the part or results of any testing e.g. battery test results, spark plugs etc. brake pads 1mm remaining, need replacement. To change things with no reapproval from me or provide cost as asked is just dodgy. It was from a deceased estate, so no idea if it was cammed or tuned unfortunately.

There were just two error codes - B1121-22 turn signals left and right (led) and U1016 Loss of ICM/ECM Serial Data Instruments. I cleared them and the turn signal codes came back but thats probably because of the led indicators.

I have had the battery professionally tested, no issues there at all. Looked at the relays/fuses and did an ohm test, they seem to be working alright.

My guess from reading on this bike, it could be the IAC or the fuel (98ron) I put in. Manual says 95, might be causing combustion issues as the mechanic noted - fouling sparkplugs.

Quoting obisteve on 10 Feb 2025 02:24 AM
Won't be the higher octane fuel in the short time you seem to have been running it. That can reputably cause plug fouling eventually but I've never had it. With the tiny tank you just pick different fuel next time you fill.

Yeah, I would be surprised but not knowing the history of the bike and whats been done to it, leaves it open to speculation until I cover some ground with known issues.

Will just empty the fuel tank and try 95ron to eliminate that as a cause. Thank you.

thefinalmasquerade
12 days ago

Quoting crowster69 on 10 Feb 2025 05:16 AM
my dyna is running about 10.2-1 comp and hates 98 fuel with backfiring and bogs down and just about stalls but loves the 95.I think a stock xr 1200 is running lower compression than that so id start with fuel.

That is good to know, I am not entirely sure of what all that has been done to it. So changing the fuel and giving that a go is definitely on the list. Thank you

thefinalmasquerade
12 days ago

**Update** It is firing on only 1 cylinder!

Checked everything from fuses/relay, battery and what not. But after doing all that testing, I started it and felt the exhaust. One was running cooler than the other.

Now to diagnose whats causing it, might just be a spark plug issue (cleanup/fouled) but I reckon I got to do a compression test as well.

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Hilly
12 days ago

Dodgy lead maybe, but, this happened to me, corrosion of the coil post where the sparkplug lead goes, worth looking mate, TPS should be ok, it really should but I think they do throw a code.

Stick with it mate, good you have the service manual, it has a trouble shooting section as well, it's a bonding experience getting a bike sorted 😁

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obisteve
11 days ago

XR1200s have twin plug heads don't they, and probably single fire ignition? Anyone know for certain?
From the shops bill, they put in 2 new plugs, well charged you for them anyway.
By all means pull the plugs, clean them and see if they fire, before you replace leads or anything else.
And no one else has said it so I will, you have of HDs great models there, once it's running well I think you'll love it.
There's a few of us on here that like Sporties, that's one of the best. Speaking from experience, for any post 1990 Sportster I'd back the reliability, general toughness, ease of getting back into service after neglect and potential for getting very long service life against any Honda made, with the exception of the Gold Wing.
Unfortunately I have a 1990 one.

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Hilly
11 days ago

Nothing wrong with sportsters, I would love to still have mine.

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thefinalmasquerade
11 days ago

Quoting Hilly on 10 Feb 2025 08:45 AMedited: 10 Feb 2025 08:51 AM
Dodgy lead maybe, but, this happened to me, corrosion of the coil post where the sparkplug lead goes, worth looking mate, TPS should be ok, it really should but I think they do throw a code.

Stick with it mate, good you have the service manual, it has a trouble shooting section as well, it's a bonding experience getting a bike sorted 😁

It definitely is, deeply appreciate the support!

Spark plugs look like they havent been changed, unless 20km ride home aged them somehow (pictures below). Though interchanging them had the same result.

Ignition coil has a crack in it, which might be the culprit. Will try and find the part locally, along with wires as they seem to have aged as well.

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