Electrical issues
Grand HDF Member
Joined: Sep 2017
Posts: 3,655
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From: Southern Virginia
Got all the service manuals, but would like to get the official electrical manual.
OP there's a trick I have done a time or two in a pinch that might be worth a try. If the internal wire is cut through, you could carefully peel the insulation back and dig into the plug a little bit, then soak each end of the wire with flux, push them together and get someone to hold them. Then apply solder and the flux will cause it to run up the wires in both directions. Hold it still and blow on it to cool it solid. If it is a good solder joint you could encase it in some epoxy (light coat), then apply silicone. Once done it's up to you if you feel like it is secure or not.
OP there's a trick I have done a time or two in a pinch that might be worth a try. If the internal wire is cut through, you could carefully peel the insulation back and dig into the plug a little bit, then soak each end of the wire with flux, push them together and get someone to hold them. Then apply solder and the flux will cause it to run up the wires in both directions. Hold it still and blow on it to cool it solid. If it is a good solder joint you could encase it in some epoxy (light coat), then apply silicone. Once done it's up to you if you feel like it is secure or not.
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Joined: Feb 2025
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2006 could probably find cheap on ebay. I bought cheap electric manual parts manuals a couple years ago, look unused. I wouldn't own a harley without a factory manual.
Nope. Sucks and that plugs is prone to leaking.
For once I agree. Again I would charge battery and see if everything is good until battery gets low.
Nope. Sucks and that plugs is prone to leaking.
For once I agree. Again I would charge battery and see if everything is good until battery gets low.
Seasoned HDF Member
Joined: Mar 2021
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From: backwoods
My point is maybe it is only partially charging. So maybe the start of the ride is fine, but the battery gets low after awhile. You need to record and clear all codes. When my stator plug broke I made it about 13 miles,battery light came on, and I made it home.
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Yes understood. Codes are cleared. Just need to find a day that doesn't rain to ride.
Seasoned HDF Member
Joined: Dec 2005
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From: poway
The voltage regulator should never let you get to 16 if working, I don't understand why LEDS matter. Write the codes down, and then clear them. You don't know when they came in.
I might charge the battery, then go for short ride staying close to home watch for check engine light. It will disappear if not up, but will be stored.
Problem is may be intermittent. But 16 volts does indicate good idea to replace volt reg. Question now is how is you charging system?
I might charge the battery, then go for short ride staying close to home watch for check engine light. It will disappear if not up, but will be stored.
Problem is may be intermittent. But 16 volts does indicate good idea to replace volt reg. Question now is how is you charging system?
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Joined: Mar 2021
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From: backwoods
So do heated gloves. Or are you saying this is more an electronics thing, some kind of harmonics, noises or something?
I am by no mean an expert on LEDs. The equalizers try to recreate the impendence of the traditional lights so it the TSM acts the same. Years ago you would speed up when losing bulb.
But I am not sure any of this will help him. Unless you have more to add?
I am by no mean an expert on LEDs. The equalizers try to recreate the impendence of the traditional lights so it the TSM acts the same. Years ago you would speed up when losing bulb.
But I am not sure any of this will help him. Unless you have more to add?
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From: backwoods
My connector frayed. I think had some making contact, can't remember, I got a battery light on dash and check engine light for low voltage, I was about 13-14 miles from home, decided to head for home. Was nervous. Made it.
Harley sells the end and about 18" of wire that you need to cut and connect.
Harley sells the end and about 18" of wire that you need to cut and connect.
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My connector frayed. I think had some making contact, can't remember, I got a battery light on dash and check engine light for low voltage, I was about 13-14 miles from home, decided to head for home. Was nervous. Made it.
Harley sells the end and about 18" of wire that you need to cut and connect.
Harley sells the end and about 18" of wire that you need to cut and connect.