Intermittent engine shut-off problem
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5th Gear
Joined: Feb 2008
Posts: 9
Likes: 0
Yes, this has been occurring since the bike was new, although fairly infrequently back then. The HD dealer was never able to get the problem isolated, identified & corrected under the MFG warranty but that is a different topic and conversation for another time. Unfortunately frequency has greatly increased to become very problematic and dangerous. Idle setting was adjusted. Again, it has never thrown an error code upon occurrence.
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5th Gear
Joined: Feb 2008
Posts: 9
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Thanks for your ideas on potential problems and solutions. "To date" I have been unable to identify & fix the problem. I am unwilling to simply throw $'s at the problem as that is an expensive game to play, and not very efficient. Any other ideas, experience or perspective anyone has would be greatly appreciated as the dealer has been of limited assistance as the problem is intermittent and does not generate error codes.
Road Master
Joined: Oct 2008
Posts: 1,008
Likes: 6
From: Jax, FL
The circuit breaker was one of the first things I considered. The bike had the 40A to 50A conversion when the HD TSB fix was issued. I have heard that if the circuit trips I would likely lose everything, lights, electrical gauges, etc.... is this correct? With my particular situation the power stays on to all electrical instruments and the ignition itself seems to just "shuts down". I can re-start the bike almost instantly, without cycling the electronics and it starts & runs perfectly until the next occurrence. Is it correct to make an assumption that if power continues that it is likely not an ignition switch problem?
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5th Gear
Joined: Feb 2008
Posts: 9
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My 03 also had the 40 to 50A recall done but it still had the problem. The issue is that you lose power for just a second while the circuit breaker trips off, and then it resets. Your symptoms are the exact same as mine, and the problem became more problematic over time. The fix is under $10 and only takes about an hour of your time. One way to see if this might be your problem is get the bike hot while at idle, see if you can replicate the problem, and then turn off all extra electrical items (stereo, spotlights, cruise, etc) and see if the bike loses power after you do that. The combination heat and power draw is what kicks the circuit breaker off for that second. The other issue is that corrosion builds up on the terminals to the circuit breaker and in the crimps. Removing that corrosion from the terminals when you replace the circuit breaker with the inline fuse solves that issue. An hour of your time and under $10 and I bet it fixes your problem. I didn't believe this was the issue with mine but ultimately it was.
2nd Gear
Joined: Dec 2009
Posts: 6
Likes: 0
From: mississippi
I wanted to wait until I was certain I had determined the true problem, the proper fix, and tested it. It turns out the problem was "thin" connector wire ends on the wires running through the main circuit breaker. Being too thin & under load they would heat up and trip the main circuit breaker. By cutting, cleaning, and reapplying new connector wire ends a problem that has been present on this bike since it was brand new from the factory has disappeared. The connectors did not visually look too "thin", dirty, or have any corrosion on them. To my surprise HD in Milwaukee has been aware of this problem for years and quietly communicating the remedy to those dealerships who inquire. Amazing the number of hours, $'s and frustration chasing a 6 cent solution. Thanks to everyone, and Hx3 who assisted me as it was a post on this forum that lead to the solution.
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