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First off replace the main circuit breaker , and when you do, get the thickest fattest ring terminal you can find, and put it on the wire going to the silver post of the main circuit breaker, it acts as a heat sink. After I did this never had another problem.
85 degrees today, hot but not all that hot and bike cut out again several times and restarted basically right away. All electrical died, no codes like before. Happened after going slow traffic lights etc. after a couple of hours higher speed ride with no problem. I have a Wards Werks fan on it and have replaced the 50 amp fuse ( last one had a crack in the case.)
What I think is happening is the heat is going back from the cross over pipe through the ventilation hole in the frame under the seat and causing the main fuse to trip. I'm thinking of wrapping the first foot of cross over pipe to try and eliminate some of the heat in this area. It's booked in in two weeks to get it remapped. I looked at the plugs and the bike is running a little lean but not all that much (plugs are new and kinda grey white) and air filter is clean.
Has any one else had a problem like this or is there any feedback or suggestions as this is kinda scary to have the bike die all of a sudden coming onto the freeway with a semi braking hard behind you!----- With Thanks
I thought replacing the cracked rear exhaust header pipe solved the problem! but no such luck!
It's a 2003 Anniversary edition electra gide classic with lowers.
There's some good suggestions listed above that make a lot of sense. I know stuff like this can be nerve racking and cause you to look for strange solutions but your crossover pipe heat theory is way out in left field. I'm sure the answer to your problem won't be nearly that strange.
Most problems are simple and so is the solution! What's difficult sometimes is finding them! Since the 50 amp breaker is only a few months old I'll start with Bill03E's idea of a thick terminal ring on the silver terminal (I put a thin coating of dialectic grease on these terminals but I don't think this would have any bearing unless it holds the heat in) I assume a thick washer would work just as well, correct me if I'm wrong and phone the dealer tomorrow about a main fuse mod.
What's frustrating is that it may be fine for days or weeks before it happens again!
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