Mine used to do that too, no fun at 70+ and bam, engine shuts off! Make a long story short, my issue was with the HD Running light/turn signal /brake light module that make them all light up, this interfered with the TSSM, (security system) sending a signal the bike is off and and security system activated. I too would obviously pull over, wait a few minutes and bike would start up.

 

I have an 06 Ultra that I drove this weekend and the power goes out with the dials shutting down and going back. The red security Key goes on for a bit then off. Its been an issue this whole summer and I am less than 2 weeks from sturgis. I have had the Voltage regulator replaced and the Power Commander. My next step it to replace the Ignition switch. If anyone has any ideas, PLEASE help!

 

I would also check the wiring under the gas tank, I have found some to rub on the frame fail and chaff a little, wearing through the harness loom. I have also found pinched wires, from the factory, in the throttle housing when I replaced my grips. I am curious if you have the run/turn/brake light module?

 

Debris in my petcock / fuel filter caused a similar situation for me in 1996. The state of California required gas companies to change formulas or add some additive to the fuel that degraded the o-rings on my new XL1200C's fuel system and within 6 months I was losing power or having engine shut downs intermittently. After a few minutes the bike would usually restart (once the obstruction settled back down into the petcock body). I learned to shake the bike back and forth for a second and it would restart. My dealership (Chula Vista HD now closed) replaced the petcock and fuel filter with better parts and better o-rings and I never had the issue again on that bike.

 

I have a friend who just bought a used 1998 HD classic. It runs fine in the city but when you get it on the interstates after a time the bike starts sputtering but does not kill. We pull over and within a very short time we're up and running again. Does anyone have any idea as to what the problem might be. The dealer doesn't and they can't take it on the highway for 30 minutes to find out. We all stopped at the same time to gas up but the problem was only with his bike.

1. Cracked fuel line in gas tank
2. Vapor lock
3. Gas cap

Any suggestions would be greatly appreciated.

 

I moved this. Couldn't figure out how to delete it.

 

Have you checked your battery connections?