Electrical issues and looking for advice

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Jan 5, 2025 | 11:42 AM

Kwikwilson007

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From: Raleigh nc

Electrical issues and looking for advice

I have a 2007 Softail that now has a 124 twin cam upgrade.. I’ve had this power commander 5 on the bike for years and it’s been a good tuner . But the bike was running terrible and I found that the packard electrical plug that normally plugs into the ecm , but has to plug into the PC5 first that’s looped into the system.. The plug has started making a bad connection and if I squeeze the plug tighter , it runs perfectly.. So I’m guessing that the connections in that plug are worn or corroded . Although they look clean and everything looks normal inside the waterproof plug . What would be my best fix for this problem?? A new tuner ? A new plug and dissemble the plug and replace all the thirty something wire ends on each wire ? Like I mentioned.. Just upon initial inspection , everything looks normal, without pulling the plug apart.. This can be a intimidating job to undergo , so I’m hesitant to start taking that plug apart.. Has anyone here replaced that plug and redone those connections before ?? If so , I need some advice on doing this .. thanks in advance..

Jan 5, 2025 | 11:45 AM

Rounders

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From: backwoods

Sometimes with connectors I criss cross them with tywraps to make a harness so they can't come apart. Would that work here?

Jan 5, 2025 | 11:58 AM

Kwikwilson007

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From: Raleigh nc

Quote:

Originally Posted by Rounders

Sometimes with connectors I criss cross them with tywraps to make a harness so they can't come apart. Would that work here?

That’s what I’ve done . When I squeeze the plug tighter , it runs fine . So I ran zip ties across it to keep it squeezed together.. That worked for a while , but now it’ll run fine one minute and start running bad again intermittently . So that rig job is no longer working…

Jan 5, 2025 | 12:06 PM

Rounders

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From: backwoods

To much dielectric grease? Can you push the pins forward, from the rear, looking for a loose one. Try to get the harness tighter? Shine a light in and use magnifying glass?

Maybe with running wiggle wires looking for loose one?

Jan 5, 2025 | 12:17 PM

Kwikwilson007

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From: Raleigh nc

Quote:

Originally Posted by Rounders

I haven’t tried that yet . The way the plug is made , All the wires come in on one side of the plug and they’re encased by the plug housing with a zip tie at the point where the wires go in at .. So I’ll have to cut the tie and start disassembly of the plug to see the backside of the plug . It’s all encased .. gonna be a Royal pain In The rear to deal with I’m sure

Jan 5, 2025 | 12:21 PM

Rounders

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From: backwoods

I am not looking at it, just throwing out ideas. I would start by just wiggling wires to see if you can find a bad one.

Also you are sure this is the issue?

Jan 5, 2025 | 02:28 PM

Kwikwilson007

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From: Raleigh nc

Quote:

Originally Posted by Rounders

I am not looking at it, just throwing out ideas. I would start by just wiggling wires to see if you can find a bad one.

Also you are sure this is the issue?

yes , I’m sure . You can squeeze the plug tighter and it runs like its supposed to .. So that’s the problem