SERVICE BULLETIN - RB Racing

SERVICE BULLETINM-1185 February 20, 2006®FUEL INJECTOR/CALIBRATION CHANGES FOR 2006 1450cc BIG TWINSPurposeIt has recently been determined that the 8˚ angle cone sprayfuel injectors used on 2006 1450cc Big Twins may cause coldstart and/or driveability problems on some motorcycles.In the interest of promoting customer satisfaction, the 25˚angle cone spray fuel injectors used on CVO 103 cu. in.(1690cc) motors will be installed on all production Big Twinsbeginning on or around February 13, 2006.Additionally, Harley-Davidson will provide for the installationof 25˚ angle cone spray fuel injectors on those motorcycleswhere use of the 8˚ fuel injectors (part number 27625-06) isdetermined to be directly responsible for cold start and/ordriveability problems. See REQUIRED DEALER ACTION.NOTEDue to changes in the manufacturing process, the part numberof the 25˚ angle cone spray fuel injector is changing from27709-06 to 27709-06A. This fuel injector also will bestamped with the words “25 DEG” for easy identification. SeeFigure 1.Motorcycles AffectedOnly 2006 1450cc Big Twin model motorcycles that exhibitcold start and/or driveability problems directly related to useof 8˚ angle cone spray fuel injectors (including those subsequentlyequipped with P&A Screamin’ Eagle 1450cc or1550cc Performance Kits).Required Dealer Action1. Adhere to the flow chart in Figure 2 when handling customercomplaints regarding cold start and/or driveabilityproblems on affected motorcycles.2. If the flow chart indicates that the fuel injectors are thesource of the problem, check the part numbers stampedon the fuel injectors. While standing on the left side ofthe motorcycle, the part number on the rear fuel injectorcan be easily read with the aid of a flashlight.3. If required, remove both 8˚ angle cone spray fuel injectorsfollowing the procedure in the applicable 2006 ServiceManual. Install 25˚ fuel injectors, either part number27709-06 or 27709-06A.NOZZLE ENDf2447x8xOld Style 8˚Fuel InjectorNew Style 25˚Fuel InjectorFigure 1. Fuel Injector Part NumbersIMPORTANT NOTEIn the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into yourdealership for either maintenance or service.ROUTINGSERVICEMANAGERSALESMANAGERPARTSMANAGERLEADTECHNICIANTECHNICIANNO.1TECHNICIANNO. 2TECHNICIANNO. 3TECHNICIANNO. 4RETURNTHIS TOINITIAL HERE©2006 HARLEY-DAVIDSON MOTOR COMPANYM-1185 1 of 2

Check the following:● Fuel has the recommended octane rating and is notcontaminated.● IAC operation.● Spark plug condition.● Engine is configured correctly (with the appropriate aircleaner and exhaust).● Vehicle configuration is supported by the correctcalibration. Refer to Calibration Information on h-dnet.com.Does the vehicle pass inspection?YESCheck fuel pressure. Isfuel pressure between58-62 psi?NOCorrect condition or installcompatible components.Are cold start or driveabilityproblems still evident?YESCheck part numbersstamped on fuel injectors.Are 8˚ or 25˚ angle cone sprayfuel injectors installed?NORefer to SYMPTOMSDIAGNOSTIC inDigital Technician.Applicable DT CodeYESNOProblemresolved.8˚25˚Replace the 8˚ fuelinjectors with 25˚fuel injectors.Update ECMcalibration.Refer to SYMPTOMSDIAGNOSTIC inDigital Technician.Applicable DT Code5388Figure 2. Cold Start/Driveability Flow ChartNOTEAlways replace both 8˚ angle cone spray fuel injectors onaffected motorcycles. Never mix 8˚ and 25˚ fuel injectors onthe same motorcycle.NOTEIf the part numbers on the fuel injectors are rubbed off or otherwiseunreadable, count the number of orifices or holes inthe injector nozzle. The 8˚ angle cone spray fuel injector hasjust three holes, while the 25˚ has six. See NOZZLE END inFigure 1.4. Update the ECM calibration. For those motorcyclesequipped with P&A Screamin’ Eagle 1450cc or 1550ccPerformance Kits, refer to h-dnet.com for the correct calibrationP/N.Credit ProcedureComplete a separate warranty claim for each vehicleserviced. Reference Service Bulletin M-1185 in the“Comments” or “Notes” section and be sure to include the VINof the vehicle on which the service was performed. Fill in therest of the claim as follows:ENTRY FIELDENTERClaim TypePRD, MCProblem Part No. 27625-06Detail Part No. 27709-06 or 27709-06AQuantity of Detail Part No. 2Description25˚ Angle Cone SprayFuel InjectorsLabor Code 5388Time1.10 HoursCustomer Concern Code 9203Condition Code 5388Performance calibrations require pre-authorization from TechnicalService to be considered for warranty coverage unlesslisted on the SWR.Upon receipt of the properly completed claim, you will receivethe labor credit shown above.M-1185 2 of 2