Hang in there dude, keep us posted on what happens[8D]
How many miles does your Ultra have??

 

Mark, this bike only has 47,000 on it. It's a new bike.

 

Bike is fixed, but I still am going to build a complete new wiring harness this winter. I don't trust this one anymore.

 

So, do we have to just guess what it was or are going to give us a little hint?

 

I know quite a few mechanics and salesman from my local dealers as well as several employees on the assembly lines and one who works in customer service at the Motor Company. I have heard of many issues with wires, wiring harnesses, connections etc. [:@] Simply put, Harley's are not wired in a very sophisticated way. Look at your bike(s), and notice how the wires are jammed, bent, pinched, and in many cases, routed in such a way as to allow them to vibrate against a sharp edge somewhere along their route. I have moved several wires over the past few years on my bikes in order to protect them better or just relieve some stress. I think your idea to replace all the wires is a sound one...too bad though, it really shouldn't be neccessary.

 

I'm an idiot. I should have done it myself! It's screwed again after only 150 miles.

I knew it was the wiring harness again, and was convinced to give it to a HD shop so they could "inspect" everything and "fix it right!" I told them once they had it open again to cut and lengthen every wire. When I get to the dealer he tells me they fixed the broken wires. Did they extend them I ask hopefully, NO, did they check each and every other wire, NO. But, the bike seems O.K., and I figure, I'll fix it up over the winter.

I pick up the bike late this morning, and take the afternoon of to go riding. After 150 clicks, the bike is running great, and I know I have work to do, so I head it home, and bang the speedo and milage counter go out. Then they start to work intermitantly. Pissed!, called the head service manager at HD, for about the 10th time, and over voice mail say enough is enough, I want a brand new harness! Damn, I paid for the 7 year unlimited warrenty, what's his problem? Then I phone the dealer and politely lose it on the service manager, telling him how dissapointed I am and that I want it fixed right! He agrees to take it back and fix it. This has been going on for two riding seasons. HD really knows how to **** of some customers. I have brought at least ten people to my dealer that have bought bikes, you think someone would notice this. I have the warrenty, so a new part isn't going to cost them, get it rather than all this mickey mouse quick fix crap.

Man, I'm pissed!, Time for a double Scotch!

 

I have a 2000 Ultra. Here was my problem and what Harley's answer to it was...
Riding along and everything would go dead..NO power what so ever.
They replaced the start relay and I forget what other relay....Still I go riding along and with no warning everthing dies...
So I took it to another bike shop (non-harley dealer), recommended by my brother, and they told me about the recall on the main breaker (40 amp) Harleys answer was you guessed it, put a larger breaker in (50amp) So far it has only quit on me once while I was white-lining through stopped traffic and running very hot (290 df) but it started right back up. On the Ultra they put the breaker, what I think is too close, to the crossover exhaust pipe under the seat. A lot of heat generated there, so I'm thinking about moving it to a cooler place. Anyhow at least that's my story.....hope it helps. Also had a buddy with a RKC having the same problem and he changed it to a 50amp breaker and hasn't had any problems since..

 

I changed the breaker a couple of years ago, and insulated in with sorbathane. I also did the recall on the front fender light wiring and holder, but that is it for "official" HD recalls. John White at HD basically (indirectly, going around the issue) told me that this harness issue is a pretty common thing, but there have not been enough incidents to warrent a recall.

I'm plenty pissed at the dealers for doing a cheap repair, really pissed at HD for not just giving me a new harness since I own the warrenty, but most pissed at myself after I knew the second time this happened what it was, and I still let someone else do a job on my ride, when I knew that I could have done it better, and only once.

 

You know the old saying.........
If you want somthing done right..DO IT YOURSELF.
It sure is a shame it has to be that way especially when you drop over 20k on your ride and then nobody knows how to fix it.
I don't mind wrenching but I would rather ride.....

 

I started tugging the wires (insert your joke here) and found the one that was causing the loss of power to the speedo, counter this morning, and since I wasn't home last night and riding right by the dealer this morning I went in, showed the tech the problem. You know what he said? Since I didn't have an appointment he could not take all the time to pull the batwing to fix the problem. It's 5 screws? I'm on my way home to get my tools and fix this problem.

Just proves that I am still an idiot to think that my dealer would actually spend 15 minutes to fix my problem? What was I thinking?