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Old 09-20-2017, 08:37 PM   #1
Sergeant Rock
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Default 77 Harley electrical or fuel problem

Hi all, my 77 Harley has an intermittent stall (engine actually stops running) when driving. The stall happens at fairly quick intervals. Almost rhythmic. Some times the cart will gain speed and hold fast throttle with no stalling. Drove around all afternoon one day with no stalling and the next day it started stalling again. The cart will run in reverse without stalling. the cart has new points and condenser, new sparkplug, new coil wire, timing is set in both forward and reverse, new gas lines, new fuel filter, new carb, new reed valve, new voltage regulator, f/r switch has been cleaned, all grounds have been cleaned, new belt, compression is 125 psi forward and 125 psi in reverse, exhaust port has been cleaned, muffler is clean, no crankcase leaks. The cart runs without stalling with the rear drive wheel raised. There is gas in the clear plastic fuel filter. Gas is new and there is no water in the tank.

If there was something loose inside the starter generator on the forward circuit would this cause this symptom. Does the power in the forward circuit route to the coil through the starter generator. I'm thinking a cold solder or intermittent short in the forward circuit. But that only makes sense if the power to the coil goes through the starter generator.
I am grasping at straws as I can not figure out what this carts problem is.
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Old 09-20-2017, 08:46 PM   #2
raydhd
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Default Re: 77 Harley electrical or fuel problem

Have you tried jumping the stop/start switch ? They can be very intermittent until they completely fail.
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Old 09-20-2017, 08:47 PM   #3
aircooled85
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Default Re: 77 Harley electrical or fuel problem

Have you checked the cut off switch that's operated by the gas pedal? It could be bad or loose.
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Old 09-21-2017, 08:05 PM   #4
Sergeant Rock
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Smile Re: 77 Harley electrical or fuel problem

I see from the electrical diagram in my manual that the power to the coil is not through the forward circuit on the starter generator but directly to the coil through the start stop micro switch and the key switch. I will have to check these switches. My cart is at the cottage two hours away so i can't check the micro switch for a couple of weeks. I will post back my findings.
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Old 11-30-2017, 08:47 PM   #5
DaleK
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Default Re: 77 Harley electrical or fuel problem

When mine had that problem is was a loose electrical connection. As the coil has to have 12 V DC constant, any interruption will cause her to stall.
Check the battery connections as well.



Quote:
Originally Posted by Sergeant Rock View Post
Hi all, my 77 Harley has an intermittent stall (engine actually stops running) when driving. The stall happens at fairly quick intervals. Almost rhythmic. Some times the cart will gain speed and hold fast throttle with no stalling. Drove around all afternoon one day with no stalling and the next day it started stalling again. The cart will run in reverse without stalling. the cart has new points and condenser, new sparkplug, new coil wire, timing is set in both forward and reverse, new gas lines, new fuel filter, new carb, new reed valve, new voltage regulator, f/r switch has been cleaned, all grounds have been cleaned, new belt, compression is 125 psi forward and 125 psi in reverse, exhaust port has been cleaned, muffler is clean, no crankcase leaks. The cart runs without stalling with the rear drive wheel raised. There is gas in the clear plastic fuel filter. Gas is new and there is no water in the tank.

If there was something loose inside the starter generator on the forward circuit would this cause this symptom. Does the power in the forward circuit route to the coil through the starter generator. I'm thinking a cold solder or intermittent short in the forward circuit. But that only makes sense if the power to the coil goes through the starter generator.
I am grasping at straws as I can not figure out what this carts problem is.
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Old 12-01-2017, 11:25 AM   #6
jonr3
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Default Re: 77 Harley electrical or fuel problem

It sounds like an electrical problem to me, although it's kind of curious that it doesn't stall in reverse. If it's the microswitch, it should happen in both F and R, which would lead me to believe it's a faulty connection at either your F/R switch, your voltage regulator, or your starter/generator.
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Old 12-10-2017, 11:46 AM   #7
73eldo
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Default Re: 77 Harley electrical or fuel problem

It could be the points are the typical crap quality we usually find today and they just happen to work ok with the reverse bias but not in forward. I hate points mostly because its really hard to find decent quality ones today.

I can't think of much else that would be different F to R especially on a 77 with the floor mount F/R switch.
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