2006 GL1800 Not running on all cylinders

[gregnva]

Hi folks,

Interesting thing happened to me riding to and from work last Wednesday - yes it was cold, in the teens, however the bike did great in the morning. Returning home, I noticed the bike sounded totally different and also seem to have a lack of engine power. The bike sounded loud, and when I got on the interstate, the lack of engine power was so bad that I found myself downshifting just to get up little crests. It really feels like its running on 3 or 4 cylinders, then I can feel/tell that for a few seconds it's running on all six, but then cuts out again back to 3 or 4.

While it wasn't overheating at all, it was definitely struggling and the gas mileage? I could literally watch the fuel gauge just move downwards. Typically it would take me 1/2 tank for a daily commute, this one took over a tank.

So after arriving home, I looked at a couple of things and made these observations:

- Held the throttle at 2k rpm, watched it jump periodically to 2800 rpm and then back down, all by itself;
- checked the oil, it was down 3/4's of a quart, replenished it (10w-40, it's due for a change, have Purple Royal to put in it);
- lotsa salt on the whole front of the bike from the road (it snowed the previous day).

AND some other things I noticed previously:

- Approx 5-8 days prior to this I noticed the gas mileage was going down (to be noticeable);
- The left (drivers side) exhaust has a leak in it ( been that way for about 12 months now);
- Aftermarket digit voltage display stopped working five days prior to this (though cig lighter is wired to it and it still works);

So here's what I have:

2006 GL1800 Audio Comfort with 2007 Hannigan trike conversion, lotsa added air tupperware and also added a usb port for the phone, along with a cig lighter. Purchased in July 2013 with 69k miles, currently it has 98,600 miles on it. Other than oil changes, bulb replacements, and washing it, no other maintenance has been done by me (e.g. air filter). Never had a problem starting it or with it running till lately.

What I did today to it to try and chase the problem down:

- checked battery connection as I had hardwired a battery tender wire and heated glove wire directly to the battery (both have fuses);
- put new plugs in (they were NGK Iradium plugs, replaced them with the same thing);, plugs that came out had a gap of right at .045", put new plugs in with gap of .039"

Results:

- Started bike up and felt an immediate engine response, and it sounded like the bike before the problem, not loud and responsive to throttle.

Ok, problem fixed right? Wrong....

After the test, I then 'bolted' the covers over the spark plugs, put the air tupperware back on, and the side covers. Took the bike out and

IT RAN NO DIFFERENT THAN BEFORE I PUT THE PLUGS IN!

So, anybody got a clue or at least a clue as to where I should go next?

Appreciate any assistance in advance.

[ct1500]

100k I would bet dollars to donuts it has an original air filter and the salt ingestion/rodent factor this time of year could be nailing the coffin shut.

[Fatwing Chris]

You mentioned salt all over everything right?Being from the north where there is lots of salt spray I can tell you that salt is a great conductor.If you have a coil or a plug wire connection that is not real good the salt can and will make your spark go to ground especially when damp/wet.The path of least resistance.In the dark you can see the spark leaking and most times you can actually hear it on the high voltage side.Only problem with a Wing is you have to get enough plastic off to see it.If you can get the salt washed off and let it dry up good and your problem is gone then your going to have figure out where it is going to ground as your original problem is still there.The salt just exaggerates the issue.As a long time auto tech I've been using a salt/water mixture in a spray bottle to find all kinds of shorts and erratic voltage issues.It works on low voltage as well.We used to use it for wheel speed sensors that generate a real low AC Voltage.Something else for you to look at if you don't get it sorted.Good luck.

[gregnva]

Thanks for the responses.

Worked on it all day today - WOW! They weren't kidding about it being a royal PIA to get to the air filter, and yes it was very dirty, but I don't think it was the original one.

So since it's tore down like it is, we started basic diagnostics. Hooked a timing light to each cylinder just to see which one(s) if any, weren't firing. The middle two cylinder's weren't firing.

Ok, now where's the coils on this thing? Did a lot of googling (I know I know, should have a service manual) and found that there's only 3 coils, which made sense in this case since two opposite cylinders weren't firing.

Located the coils through the front of the bike (take the top black panel off). Changed the middle coil with the passenger side coil, and the middle cylinders were now firing but two other cylinders were not.

Ok, we proved the main problem is a bad coil. Now just have to find one.

Well..... that's a whole other story. It appears that there's a nationwide backorder on them and I can't find one anywhere (there's a couple of used ones on ebay from the UK).

Anybody know where I can get one from within the States, new or used, FAST???

[gregnva]

Aha, good friend of mine found used ones from a 2008 GL1800 from a salvage yard in Michigan! Whoo Hooo! Ordered all 3 on ebay (ten bucks a piece and free shipping).

[gregnva]

So in thinking about causes for the coil failure, one thing I failed to mention was that I had additionally washed the bike and I always clean the timing cover plate in front of the engine and all of that, so I can only surmise that this had been detrimental to the coils and then add the salt and bingo... problem. (Then again,m the coil could have just failed by itself without external forces).

Well then, in thinking why our gas MPG might be going down, we have to consider a failing coil.

In my case, I'm sure that a) spark plugs needed to be replaced; b) air filter needed to be replaced and c) I had a failing coil (or as the last straw it failed in the end just to fu__ with me).

So, when you lose MPG's, consider my experiences here.......

[deepsix777]

Check out cyclemax.com they have them new @ 106.90 apiece

[gregnva]

Thanks, while I didn't find them on their website (yet), based on all my calls today, vendor websites list they have them, but when you call them, they confirm they are on backorder. So just because a website says they have them, and you can order them, doesn't mean you'll get them when you think you will. It's always best to call them to find out.

But I do appreciate your response.

[deepsix777]

Your welcome if for some reason you need them in the future look under 1800 OME Ignition coil part #30510-MCA-S41.