Apparently my reading comprehension is somewhat lacking at 5:30 am!!!
Sorry about that OP.

 

That is what I would do...just run a new wire for a test...if that solves the problem permanently replace the wire.

 

I believe he said he did that.
But yea only place it could be.

 

Touche'

If you have access to a megger, you may want to check the resistance of the stator to ground.

 

Thinking outside the box so just throwing ideas.
What in the system would not like 14.5 volt instead of 12.
You say you cleaned up ALL of you connections on the bike, dielectric grease, and all the grounds?
Ignition, voes, I don't think the coil is grounded at point of installation or the cam sensor, those are grounded at the ignition.
It has to be something with the ignition.
What kind of voltage reading are you getting on the battery as it is running both vr hooked unhooked.
I don't believe I read that number, don't make me go back and reread:-)

 

Thanks again fellas for putting your gray matter to use over this.

Dr. Hess the tach is erratic when the VR is plugged in and the bike is running but rock steady with the VR unplugged and running.

Tom, I have run a continuity test and get a positive reading between the VR and ground.

Harleycruiser, this idea is what I have been thinkin g about for the last couple days and so decided to replace the remaining three circuit breakers in the system. No luck. I did spend some quality time sniffing around last night and found two wires that were mildly suspect. One was the VOES lead back to the control module. A blade connector that was loose and slightly corroded. The other is the BAT positive lead to the main breaker. One end of the wire has the wires exposed a little nothing big but I'll clean it up anyway and put a new connector on it.

I guess the next level is to drill out the ignition cover and make sure everything is right in there. I need to test the ignition sensor ground.

I can't get an accurate reading on the voltage at the battery with it running (sputtering) before it dies and with the VR disconnected there is nothing going back to the battery. I do get a reading from the stator with the multimeter when it is running. It is within specs per the manual and increases with RPM.

 

Ok there are a couple of things that don't make sence. My schematic shows the be wire going to the main breaker not the battery, can you start taking photos so we get a better visual.
Do you have a factory manual with a skematic, get a photo of that.
Did you ever replace the wire going from vr to breaker/bat?

 

HarleyC, You are right, the wire goes back to the AUX side of the main breaker. I have two service manuals (one for FXR and one for 1340 EVO) each shows a slightly different wiring diagram. One puts the VR to the AUX side of the breaker and one shows the VR going to the BAT side. When I got the new VR from Harley it had instructions to attach the VR to the AUX side of the main.

The wire from the VR to the breaker/BAT has been replaced twice with each new VR.

 

Run a new wire and let us know.

 

I think you are on the right tract there.
We have been looking at this like it was a charging issue, I think we should be looking at a running issue that does not like the extra voltage.
Would not be the voes or the coil, not likely the cam sensor, only thing left is the ignition module.
My bet is when the vr went bad a voltage spike took something out in the module.
Yea take the cover off see if you smell anything see anything fried.
I have a module off a 86 sportster, I have been told that they are interchangeable, the fxr has a higher rpm, and advanced timing.
It has your name on it if you are interested. it has been sitting on a shelf for fifteen years is not doing me any good.
Let me dig it out and get a number off it.