throttle-by-wire limp mode
Tourer
Joined: Mar 2008
Posts: 435
Likes: 2
From: Alberta, Canada
The broken wire was in the sheathing just under the throttle body. The wires make a sharp bend, which appears to cause a weak point where the wires break - probably with the help of heat and vibration.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
I guess I should check mine because when I added the SE A/C, the support bracket is removed and the wires/clip are just hanging there.
Road Warrior
Joined: Feb 2010
Posts: 1,534
Likes: 10
Funny you mention that. When I installed my SE A/C, I removed the metal bracket & plastic bracket and zip-tied the three wire bundles together.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
I guess I should do this before something happens!
I know this won't repair a broken wire or keep one from breaking, but on another thread that was addressing this problem it was suggested that putting di-electric grease on the connections would help fight the corrosion. I have done this on the ECM and the connector to the throttle body. One question: Is this a problem that is only common to the '08's or is it happening on the later models also? I have an '09. I'm curious if the throttle grip sensor has been upgraded on the later models. As for as TBW goes, cars and trucks have used it for quite a while now w/o too many issues (Toyota maybe being one). Hopefully the MOCO will get it worked out as it seems this is the direction they are headed with all models.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
Although I have had no problem,I know the wires must be bouncing around.
Tourer
Joined: Mar 2008
Posts: 435
Likes: 2
From: Alberta, Canada
The wires on top of the throttle body (for the injectors) are attached to a bracket. The wires we're talking about aren't attached to any brackets. These wires loop under the throttle body and terminate at the large plastic clip behind the left side of the air cleaner.
H-D may have changed the wires to something more pliable or less brittle on newer bikes, but they didn't change the routing or supporting of the wires. My '11 Ultra has the same setup with the tight bend in the wire. I carry crimp wire connectors in my tool kit, just in case it bites me again.
H-D may have changed the wires to something more pliable or less brittle on newer bikes, but they didn't change the routing or supporting of the wires. My '11 Ultra has the same setup with the tight bend in the wire. I carry crimp wire connectors in my tool kit, just in case it bites me again.
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Road Warrior
Joined: Feb 2010
Posts: 1,534
Likes: 10
The wires on top of the throttle body (for the injectors) are attached to a bracket. The wires we're talking about aren't attached to any brackets. These wires loop under the throttle body and terminate at the large plastic clip behind the left side of the air cleaner.
.
.
I clearly see the sheathed sets of wires under the tank, as well as the single sheathed set of wires that terminate with a connector to the left side of the A/C.
I pulled back the sheaths on all these wire sets about half an inch, and did not see anything obvious that look broken or split. There also weren't any funky bends or kinks that I could see.
I took the connector off the left side of the A/C, had a peek at the pins and terminal, and reattached it. Nothing obvious here, either.
Is there anything else I should look for, or is that all I can do for a cursory inspection?
Thanks