Please update us once the problem has been solved.

 

check the ground connections on the other end by the starter as well.. my ground strap end was cracked..it looked good and tightened..but the "ring" had a crack in it.. Replaced the cable and all was good.. .

 

Well Its not solved ......YET, but I'll give you an update

I got ambitious yesterday morning and pulled the primary cover off, the chain, the clutch and the front sprocket, removed the stator cover and checked the stator itself....it looks brand new

I was going to open up the Fairing to see if anything was loose inside there (if I figure out what goes where in that sea of spaghetti, LOL)

When I went to the dealer this morning the parts guy mentioned to check the coil, to him it sounded that it may be the culprit, "especially under a load", as he put it. I've printed out both the Dr. Hess's "How to Diagnose your charging system" and Harley Manual 6 "How to test a Harley Davidson Ignition Coil"....I'll be performing both of those tests tonight AFTER I check the starter ground to ensure its not damaged and snug.

I'll report back with my findings

Thanx again guys

 

Dr Hess instructions helped me. And recently got some good advice.
https://www.hdforums.com/forum/touri...to-itself.html

 

I looked at the picture you took of your Stator.....what exactly was wrong with it?

 

It was shorted out. When I opened the primary the compensator nut was finger loose and the rotor was banging on the stator. The rotor magnets on both were all beat up. I tested the stator before hand and showed it was shorted.

 

My Stator, Backside

 

check the main harness on right side of the tank I just went thru kinda the same problem with my 2000 flhtpi when i turned to the right it would cutout and stall, turned out to be broken or near broken wires (7 in all), the way they have it clamped on the steering head it causes a tight bend and the wires on the inside of the loom were being bent hard and breaking. I had to cut and splice 7 of them and rerouted the harness so it didnt make that bend I eliminated the clamp on the steering head here is a link to my post...good luck
http://https://www.hdforums.com/foru...ll-switch.html

 

opened mine up and same problem. nut on the crank shaft was looooooose and the rotor was hitting the stator. the mag's are all messed up. going to cost me some money fun.

 

I'm impressed with how far into this you got. Hope you didn't go entirely on my first suggestion - seems it might have been a bum steer.