I had an electrical fire today at the wire harness behind the voltage regulator. [2004 FLHPI] Has anyone else had a similar issue? I was lucky to only be 1/2 mile from home and was able to put it out with some wet grass/dirt. I'm not sure even where to start diagnosing the root cause. I am also curious what the best fix is (without replacing the wire harness.)
Any input is appreciated.

 

Glad to hear you were able to put it out - luckily there is limited amount of smoke in the wires, and once it is out , it stops...


Most likely some wires chaffed and shorted, melting the insulation. You'll have to look at the burned wires and look for evidence. Was it the wires to the alternator, or the two going to the battery/main harness? You may be able to repair them, but the ones going into the motor/primary are short and come with the stator, I think...


Good luck, follow up with details and pictures and you'll get good advice from people here.

 

Goodness gratish great ***** a fire....glad your ok tho.

Batman

 

I just had this very thing happen a couple of weeks ago. Came back from a ride, pulled into driveway and smelled burning wires. My voltage regulator was dripping molten black smelly stuff. I about fouled my britches... Insulation on hot wire to reg. was worn thru. Cleaned it up and plugged in another regulator and BAMM I'm ridding again. If yours was the reg. melting the smell will be your clue. Good Luck

 

Thanks everyone. Taildragger NC, that is exactly what I saw and was smelling. I'll post some pics when I get time to tear into it. Glad I have my Aprilia Mille R so I can still enjoy 2 wheels. I called Harley today to see if they had any input. Due to the age of the bike they said they could not do anything except document the incident. The guy I talked to seemed genuinely concerned and said he has not heard of this happening before. This is why I love this forum. So much knowledge and great people to help.

 

It was this forum that helped me too...If it is the Regulator check with a independent shop. Sometimes they have perfectly good takeoffs at a huge discount.

 

Found the culprit. As expected, the voltage regulator. Still need to clean and check the surrounding wires/connectors but I think I got lucky this time. More to come...

 

It's always good to find the "smoking gun" when troubleshooting a problem. Glad it wasn't worse.

 

Got to quit giving my buddy so much crap about his 2004 Classic catching on fire. Same thing, voltage regulator. Used to tell him he was the only one I know, that their bike caught on fire. Luckly a woman stopped with a bottle of water and he put it out.
Turned out his Indy used an aftermarket Voltage Regulator so he was told.....put a new one on cleaned up the wires, and wiped off the smoke and he was back on the road.