plug wire caution
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Cruiser
Joined: Feb 2012
Posts: 202
Likes: 4
From: new york
plug wire caution
while doing a service on my 2015 road glide I came across an issue with the front spark plug wire.It appesrs it rubs the gas tank seam in front.mine was worn half way thru.I checked three other bikes in the family and each had the same issue.just putting it out there.
Cruiser
Joined: Sep 2014
Posts: 157
Likes: 1
From: Cedar Rapids, IA
It's been posted before, but never a bad reminder for those that may have not seen it.
I had the dealership look at mine and they were supposedly going to replace the plug wire for me. Which reminds me I should call and check on getting that done.
I had the dealership look at mine and they were supposedly going to replace the plug wire for me. Which reminds me I should call and check on getting that done.
Yeah. I noticed this too on mine. I caught it before it frayed completely through. It's from the factory zip tying front plug wire to the left side of the frame under the gas tank. The fix is to relocate to the bottom center of the frame just above the front rocker box of the engine.
Cruiser
Joined: Sep 2015
Posts: 187
Likes: 2
From: SW Florida
Checked mine on my 2016 Ultra Limited Low and it has the beginnings of a mark, not rubbed through but it would have. I just turned 2,000 miles on the odometer. I took some wiring harness loom the light kind that you wrap a wiring harness with. It is small enough to just fit around the plug wire and is a spiral cut so it wraps around the plug with and wont move.
Those looking for it can find it at radio controlled airplane sites. It is used to route ignition wires for the gas powered model planes so they don't get rubbed through by vibration.
I also put a small piece of that 3M clear protective film on the bottom of the gas tank where the plug wire touches so it will help protect from rubbing the paint finish.
Pretty poor design issue on Harley's part as clearly this is another known issue and they still continue to build the bikes in the same manner without correcting this flaw.
Those looking for it can find it at radio controlled airplane sites. It is used to route ignition wires for the gas powered model planes so they don't get rubbed through by vibration.
I also put a small piece of that 3M clear protective film on the bottom of the gas tank where the plug wire touches so it will help protect from rubbing the paint finish.
Pretty poor design issue on Harley's part as clearly this is another known issue and they still continue to build the bikes in the same manner without correcting this flaw.
Last edited by BillJ; Oct 4, 2015 at 12:45 PM.
Checked mine on my 2016 Ultra Limited Low and it has the beginnings of a mark, not rubbed through but it would have. I just turned 2,000 miles on the odometer. I took some wiring harness loom the light kind that you wrap a wiring harness with. It is small enough to just fit around the plug wire and is a spiral cut so it wraps around the plug with and wont move.
Those looking for it can find it at radio controlled airplane sites. It is used to route ignition wires for the gas powered model planes so they don't get rubbed through by vibration.
I also put a small piece of that 3M clear protective film on the bottom of the gas tank where the plug wire touches so it will help protect from rubbing the paint finish.
Pretty poor design issue on Harley's part as clearly this is another known issue and they still continue to build the bikes in the same manner without correcting this flaw.
Those looking for it can find it at radio controlled airplane sites. It is used to route ignition wires for the gas powered model planes so they don't get rubbed through by vibration.
I also put a small piece of that 3M clear protective film on the bottom of the gas tank where the plug wire touches so it will help protect from rubbing the paint finish.
Pretty poor design issue on Harley's part as clearly this is another known issue and they still continue to build the bikes in the same manner without correcting this flaw.
Last edited by fltrxcrzy; Oct 4, 2015 at 01:11 PM.
Elite HDF Member
Joined: Jun 2007
Posts: 4,867
Likes: 268
From: People's Republic of Boulder Colorado
Every Rushmore bike built to date has this problem straight from the factory, and most likely will continue to have it for god knows how much longer.
I already knew about it and zip-tied the one on my '15 Limited out of the way before I took delivery (nothing like lying on a less-than-pristine showroom floor while fixing one of several ongoing and well-known design defects on a brand new, $27,000+ vehicle).
It's absolutely idiotic that the MOCO hasn't addressed this super-simple problem and fix, but that's typical of them, I guess.
They're probably just too busy trying to convince people that the radio, bag attachment fittings, hydraulic clutch system, headlight etc. etc. etc. on these vehicles are the greatest ever!
I already knew about it and zip-tied the one on my '15 Limited out of the way before I took delivery (nothing like lying on a less-than-pristine showroom floor while fixing one of several ongoing and well-known design defects on a brand new, $27,000+ vehicle).
It's absolutely idiotic that the MOCO hasn't addressed this super-simple problem and fix, but that's typical of them, I guess.
They're probably just too busy trying to convince people that the radio, bag attachment fittings, hydraulic clutch system, headlight etc. etc. etc. on these vehicles are the greatest ever!
Last edited by jpooch00; Oct 4, 2015 at 02:24 PM.
Stellar HDF Member
Joined: Nov 2008
Posts: 2,432
Likes: 290
From: FL
Yup, caught the same issue on mine about six months ago. I wrapped the plug wire with fuel line at that spot. I posted it here as well. Thanks for looking out.
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Elite HDF Member
Joined: Jun 2007
Posts: 4,867
Likes: 268
From: People's Republic of Boulder Colorado
The fenders on the Rushmores seem pretty thin and flimsy to me, the tank may be, too.
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Road Captain
Joined: Nov 2009
Posts: 698
Likes: 13
I for one am glad this was mentioned.......I just looked at mine and sure enough, the front plug wire has a wear spot on it from rubbing the bottom of the tank. Bike only has 3,200 miles on it. Glad this was mentioned and I checked as we are taking three days next weekend and making a long weekend out of it. I'll be sure and resolve that beofre we leave.