Sportster 951DI won’t stay running

[FirstSeadoo]

Hello all, I’m a newbie here. I just picked up a 04 Sportster LE DI (mechanic special) - so the thing is in beautiful shape so I figured I would try it out- story goes - it ran great but the Bendix would stick so he decided to bring it in to the local marina where they also decided to change the stator since they would be in there. Well- since he got it back now it won’t idle and just dies.. if you can get it to start and rev it up it will stay running but if you idle it instantly dies. So I haven’t done much since I got it but if I turn it over it instantly fires but just doesn’t start and when I did get it to start it was rough and I shut it down. Pulled the plugs and it looked like only the forward was firing (wasn’t wet) pulled off the rear and it was wet with oil. Pulled off the air box off the throttle body and noticed the same cylinder had oil on the throttle body. Also pulled the rave covers off and they are full of oil. The cylinder that appears to be firing is also has carbon mixed with oil but the other is just clean oil. So my question is . Where the hell do I start? Don’t wanna pull the engine yet to check the stator job they did, I’m hoping something else maybe just either went out or didn’t get out back right. - any help or advise would be greatly appreciated!

 

[jhjesse]

Does the maintenance light come on? Anything electrical will throw a code.
Most fuel related issues will not throw a code.

Have you performed a compression check?

 

[FirstSeadoo]

Does the maintenance light come on? Anything electrical will throw a code.
Most fuel related issues will not throw a code.

Have you performed a compression check?

Haven’t done a compression check yet. And no maintenance light I’m aware of. Not even sure if this has one? I’ll try to do one soon and post the results
Thank you

 

[FirstSeadoo]

Haven’t done a compression check yet. And no maintenance light I’m aware of. Not even sure if this has one? I’ll try to do one soon and post the results
Thank you

Does the maintenance light come on? Anything electrical will throw a code.
Most fuel related issues will not throw a code.

Have you performed a compression check?

Bought a harbor freight compression tester and it was showing. 80 psi in both cylinders, seemed ofd they both would be that low so I went and got a borrowed one from the autozone and front cylinder now shows 122 and the back one is at 125 psi. I’m not sure if this is accurate either? Engine wasn’t warm (obviously-won’t start)

 

[jhjesse]

DI engines only fire on one cylinder at idle.
Did the marina install an aftermarket stator? If so, most of the ones I have seen are cheaply made and don’t hold up.
Are you getting a maintenance light?
If no maintenance light and getting good spark then you probably have a fuel issue.

 

[FirstSeadoo]

DI engines only fire on one cylinder at idle.
Did the marina install an aftermarket stator? If so, most of the ones I have seen are cheaply made and don’t hold up.
Are you getting a maintenance light?
If no maintenance light and getting good spark then you probably have a fuel issue.

I believe the spark is good, but I’m going to try a new set of plugs tomorrow. What cylinder does it run on in idle? Does it also only start on one? One thing I did do however, is I poured a teaspoon of gas mixture in to the throttle body and it did fire up really rough but it did start for 10 secs and died as soon as I touched the throttle. I pulled the cover off the ignition coils and also noticed a bit of condensation.. not sure if that has anything to do with it yet. I’m really hoping it isn’t a bad stator.. I’m not sure what they put in I didn’t ask the old owner. But i do know is that he said it ran like this since he got it back, unless full throttle across the lake he said or it would die. He hasn’t put it back in the water nor have I. Thanks for the info and sorry for all the questions !

 

[FirstSeadoo]

I believe the spark is good, but I’m going to try a new set of plugs tomorrow. What cylinder does it run on in idle? Does it also only start on one? One thing I did do however, is I poured a teaspoon of gas mixture in to the throttle body and it did fire up really rough but it did start for 10 secs and died as soon as I touched the throttle. I pulled the cover off the ignition coils and also noticed a bit of condensation.. not sure if that has anything to do with it yet. I’m really hoping it isn’t a bad stator.. I’m not sure what they put in I didn’t ask the old owner. But i do know is that he said it ran like this since he got it back, unless full throttle across the lake he said or it would die. He hasn’t put it back in the water nor have I. Thanks for the info and sorry for all the questions !

Also I forgot to ask is the 120-125 to low for these machines?

 

[jhjesse]

So compression is borderline, but it should still run fine. Should be 135 to 140.
As far as which cylinder it runs on when at idle, it is random.
Here is my thoughts, the boat was running good except for the starter bendix.
Changed the stator and now it doesn’t run...
Anything electrical should throw a code, but there is no maintenance light...hmmm
Might go back and check/verify all electrical connection good especially the crank position sensor plugged into the front of the stator cover.
The only other thing is fuel.
You could try changing the fuel filters. There is two filters on/in the fuel pump and one on the fuel supply to the fuel rail. You would have to pull the fuel pump and replace the internal filters.
They can be purchased at most any auto parts store.
Airtex FS220 and FS242
The external is a dealer item it comes with the hoses and is very expensive. I personally just cut the filter out leaving enough hose to install a WIX 33095 metal canister filter with two stainless hose clamps. Changing the filters is not a bad job and should be done periodically to maintain a healthy pump.

 

[FirstSeadoo]

Thangs again for the info, I went ahead and pulled the fuel injectors and tested them on battery... the forward injector sounded super weak compared to the other. I soaked them in cleaner and kept activating it till it started sounding like the other one. Fingers crossed this thing fires up. I got the fuel filters on order and new orings for the rave valves and then I’m going to fire it up. Fingers crossed that’s all it takes. Would you recommend also. Dumping the fuel and replacing it before the start?