This^^^^^^^^^

 

Thanks, I will make sure to use the correct wires. I guess that is a good example of how an amateur can mess things up by not know what is important and what is not important.

 

[QUOTE=Sorg67;16292354 the neutral light does not work (bulb is good) and blinkers work intermittently.[/QUOTE]

Check the ground wire to the frame from the neutral switch. I swapped 'em out and no luck. Then found the ground wire broken off where it mounts to the frame. Works very well now.

I had blinker issues like yours. Work/not work. Swapped out handlebar controls for newer ones. Same issue. Swapped out the TSM and works like a charm. Try that.

As to the trip.. I did 4200 miles two up, pulling a cargo trailer on my non-stock 94 ultra a few years back in 18 days and didn't even add any oil to it. I use it for my road trips as it is setup the way I want it for cruising. Larger motor, six speed, etc.

I am also a AAA Premier RV member which gives you 200 miles of free towing if needed.

Griz

 

I'm going to drop this here for you:
If it ain't broke.......... tear it apart and find out why.

 

I've done 2-3 1000 + mile trips a year with the current '94 for the last 12 years and have never used a tool I packed. Broke down twice - stator both times and that's not a roadside fix. I haven't carried any tools for the last 3 years.

 

That is precisely my mechanic's perspective.

 

I recently replaced the stator (at about 50,000 miles) How long do they usually last? Is that something to consider replacing every so often as a preventative measure?

 

Where exactly is the neutral switch. I have been looking for it and cannot find it.


I have checked the ground to the frame under the seat and it appears fine to me on a visual inspection. Is there a way to check it electronically?

 

It's inside your transmission.
If you look under your oil tank you will see a brown wire with a cup like fitting on it.
That wire is connected to your neutral switch.

 

They also tend to work on numerous bikes at the same time. Parts get 'misplaced' in the process. On the plus side, an experienced mechanic does know all the 'tricks' to get things done. They have to deal with impatient owners that want their bikes back, so I'm not without understanding.
Exactly. My biggest problem (once I've dealt with anxiety issues) is tracking down 'that part'. Especially hard on older bikes, if you want to keep it as OEM as you can. And honestly, the aftermarket, produces some good replacement parts. And some bad ones to. Just have to be careful.
Before I'd go tearing into a total re-wire, I'd first check every ground point. Most electrical gremlins are caused by poor (or no) grounds.

Since you stated the bike spend some time exposed to the elements: Your neutral light issue might be a bad connection at the top of the transmission. Blinkers: I'd check the bulb sockets for corrosion. Clean with a bit of fine emery cloth. Dielectric grease is your friend. I need to go over all the bulbs/sockets on my bike and clean/grease.

I have never looked at the wiring diagram for a FLSTC, but I have seriously studied the ones for the FLHS, FLHTC, FLHTCU, FLTC, and FLTCU. The full blown E-Glides have a lot of circuits/wiring. The FLHS is far simpler. I would imagine in complexity, your FLSTC compares to my FLHS, in circuits/wiring. Helpful Hint: Take the FSM wiring diagram down to FedEx Office and use one of their enlarging copiers. Blow that puppy up to a 'user friendly' size. Make multiple copies. You can then use colored markers to track circuits. Keep one copy unmolested so you can make additional ones if needed. I did this when I was figuring out how to HackFab install a Harley electronic cruise control kit (for a FLHTC) unto my FLHS.

That being said, unless your looking at a charred tangle of wires, I'd first just look at the connectors for corrosion. Clean (you can get aerosol electronics cleaner) them. Use some steel wool wrapped around a pipe cleaner or a Q-tip if necessary. Some of the terminals can be brightened up a bit with emery cloth.

Good luck, and start a thread if you run into problems. Post pictures!!!

Oh, and I've done a bit of wiring: