As I told you on my Oct 05 post, you should really try removing the front lowers and the bike and trying it. I assure you that my bike was doing the exact same thing and after removing the lowers I have not had the problem again in 7 years.

 

The problem with removing the lowers is that you really haven't fixed the problem. The bike is made to ride with the lowers in place and you shouldn't have to remove them for the bike to run correctly. The replacement of the main circuit breaker with a fuse mounted in a different location on the 04 and later bikes shows this was a design problem that Harley elected not to fix on the 03 and older bikes.

 

Just completed two hour, non-stop ride in 95 degree temps with everything powered up for the entire ride. Lots of stop and go.....bike ran like new the whole time. I'm very certain that the main circuit breaker behind the rear cylinder is what was causing my problem, even after the recall to replace the 40 amp c/b with a 50 amp. Hope this thread will help folks in the future having similar issues.

 

Maybe the lowers are designed to be left on, but frankly I don't understand how the average rider can stand the increased heat on the legs due to restricted ventilation with them on in the summer months. My legs have gotten so hot before that almost caused blistering of the skin. My solution of removing them in May and re-installing them in October both solves the engine overheating issue, but makes riding in the summer so much more comfortable.

 

Hx3,
Can you post step by step instructions on this? This happened to me yesterday going 65mph on a busy interstate. The recall has been done on my bike as well. Been reading posts of the fix, but have not found details on how to do it.
Can you help?

Dave

 

You may want to start your own thread on this subject as this is a 3+ year old thread.