I have a 2000 Ultra Classic and have been having an issue with the electrical system just shutting down while riding. I have the bike in the shop at the moment and they are not sure what is causing my problem.

The HD mechanic said the Circuit Breaker was heating up to 150 degrees and this was causing it to trip. They just weren't sure what was causing it to heat up.

Anybody else experienced this issue??

 

Well I don't have experience with your concern, but I do with electrical diagnostics. You can take an inductive amp meter and see where most of the current is going, that will get you in the general location of the high draw, then disconnect one component at a time. Through the process of elimination you can figure out the suspect component. Very time consuming, I know, but you will find the issue. Also pay attention to rub/chaffing areas that the wires route through.

Another thing to look at are the connection terminals, look for discolored terminals. loose connections build up heat and increase current load. An inferred thermometer may help locate the general area.

 

I believe that Harley has have had several recalls for undersized main circuit breakers for a while. I had it happen to my '93 ultra.Went to start it, and it was like someone stole the battery out of it. The dealer replaced it with a larger one and that cured the problem. It might have been a 30 amp, and they put a 40 amp in it's place.,,

 

There was a recall on the tourers concerning the weaker Main CB, also over a period of time CBs will weaken thermally and may not be able to carry the designed load.

 

You need to replace the ring terminals to the biggest ones you can find , this way they act like a heat sink, and put the new c/b in , and you should be good.