Cmplete Loss of Electrics

[Mulsanne]

Loss of All Electrics

Hi Guys... I've just purchased an '03 Road Glide and I'm having a blast. There is one problem though. I drove her home and whilst in stop and go traffic, the electrics just quit. Everything went dead and the motor stopped. I put the bike in Neutral, put the kill switch to off and turned off the ignition.

I then started the bike as normal after about 5 seconds and she started, only to do the same thing again, everything dead. I found that if you kept the RPM up, she would run and I limped home, through a built up area, gunning the throttle (made me really popular as it was 11pm).

I suspected the battery as the voltmeter showed only 10v when you turned on the ignition, so purchased another Harley battery. Started and ran without fault for another 3,000kms.

On this last trip, I ran for about 150kms, oil temp around 210 and had to stop for some construction, I didn't note the oil pressure though. The bike went dead again. I tried the old trick again and waited for a suitable gap in slow moving traffic, then set off keeping the rpm around 2500. No problems at all. Because of the location and lack of any shops around, we decided to press on and ran faultlessly for another 800kms.

When I got to the next major city, I had rush hour traffic to contend with and she quit again. This time I was not able to keep any speed up and had to wait until the traffic thinned out before I set off again. Once under way, no problem at all.

I got to my destination and booked the bike into a shop that specialized in Harey Davidson. No codes showed up and the Thundermax igition system that was installed by the previous owner, showed no codes.

The tech cheched out the posative and negative terminals to the battery, as well as the ground connections that he could see and find, without stripping the bike. It started and ran for him every time.

I rode 900 kms home without incident. The temperature remained around 200, the volts were up around 14 and the oil pressure great. Loads of power and not a hint of a problem.

The engine was rebuilt to 106cu about 20,000kms ago and the Thundermax ignition installed at that time. The only problem that I have noted is that the aftermarket LED driving lights operated by the ACC switch on the dashboard work intermittently due to a lose wire at the switch (I turned them off). Apart from that, the bike is amazing and all systems work as normal.

So.....there you have it. My main concern is that this loss of all power will happen crossing an intersection one day. I hope that someone will be able to help me with this. I have now tried 2 shops and no faults appears while they are testing the systems.

Cheers, Martyn

[War Horse]

Well it sounds like either an ignition switch or a wire on the stator making intermittent contact, Seems the igy switch is more likely tho.

Oh , welcome to the site.

Might also be in the wrong catagory, should be in TC or general.. Its cool , I'm sure it'll get moved straight away.

[kik]

Could it be the main circuit breaker heating up and cutting out??

[War Horse]

Could it be the main circuit breaker heating up and cutting out??

Thats a good call.

[slypig]

Could it be the main circuit breaker heating up and cutting out??

Thats a good call.

Lots of issues with that circuit breaker.

[iconicbikesrider]

I had the same issue with a '05 Springer Classic. The symptoms are exactly the same. Newer bikes do not use a Circuit Breaker anymore. They have a SuperMax 40 Amps fuse.

Find out where the Circuit Breaker is located and replace it with a 40 Amps Circuit Breaker sold in any Auto Store for about $6. I did that and resolved my problem. Hoping this advice works for you.

A bit more info. In all electronics there is a +/- tolerance. In addition to the quality of the device. Appears to me that H-D used low quality CB and the results is that it was a "recurring" problem with a ton of bikes.
Using a no-more than 40 Amps will not damage your bike.

[ViennaHog]

check the circuit breaker for heat. An insufficient crimp connection at the lead to the circuit breaker heats up the the breaker and causes it to trip. A large number of 2003 FLH bikes were affected. Took me some time and help of the forum to figure that one out.

[dakota224]

Not to steal his thread but where is the circutbreaker located on a 05 fatboy? same thing happening on ol ladys fatty.??

[ViennaHog]

rear fender inner splash guard AFAIK

[Old Crow]

Must be the summer for bad breakers.  Had to replace the OL's headlight breaker on a trip to Tn earlier this month and I just replaced the main breaker on my Shovel bagger last week.
For what it's worth(apples to oranges)my Shovel was doing almost the exact same thing as the OP's bike.

[harleyjt]

Could it be the main circuit breaker heating up and cutting out??

Thats a good call.

Lots of issues with that circuit breaker.

I had the same issue when I had my 02 Ultra.  In fact, there was a recall for this very issue on many of these bikes to replace the problem breakers.  Iirc, they were replacing the 40A breaker that came on the bike with a 50A breaker.  Does anyone else remember it that way?   I do not recall off hand if the 03's were involved in that recall or not, but I do remember 02s were.  It wasn't until 04 that the CB went away in favor of the current 40A maxifuse setup.   I also remember that some guys prior to the recall, were actually getting rid of the breaker and wiring in a 40A maxifuse themselves to get rid of the problem.  Of course the maxifuse doesn't reset itself like a CB does. It has to be replaced. 
jt

Edit - I looked here and the HTT recall docs don't go back that far.  I googled Harley recalls and found that Recall #113 does apply to at least some 2003's.  See here - http://www.recallsfinder.com/index.php?year=2003&make=harley+davidson&model=fltri 
Note it seems the recall may only be for fuel injected models?  I tried the std FLTR and one other carbed model and they did not appear to be involved.  Not sure from your post if yours is efi or carb.

[truck]

My 2001 Ultra had the same breaker problem. I bought the new 50amp breaker and installed it myself rather than tying up the bike in the dealer's shop. It was only about four dollars I think.

[CndUltra88]

Call you dealer and see if they have done the recall done for the for the circuit breaker.
Have your serial number ready ...
Then get the part number and head to your local automotive shop and pickup a new one for less money than the dealership.
Should solve your troubles.
50Amp is the upgraded one.
Rob

[ViennaHog]

Please check the crimping as outlined earlier if the circuit breaker heats up with little load on it. Simple test by hooking up a batterie charger and leave the igntiton on for say one hour. When the breaker gets hot to the touch there is a problem

[tbird]

Where is that circuit breaker located on a 02 ultra?

[harleyjt]

Where is that circuit breaker located on a 02 ultra?

On the frame in front of the battery area. Pull the seat and look down.
jt

[Mulsanne]

Thank you both for your interest in my problem.

After a few hours digging around on-line, I looked up recalls. It appears that in 2004, there was a recall (04V134000) for my bike.

I've pasted below the recall:

Build Years/Makes/Models:    1999 - 2003 HARLEY DAVIDSON FLHTCI
1999 - 2003 HARLEY DAVIDSON FLHTCUI
1999 - 2003 HARLEY DAVIDSON FLHTPI
1999 - 2003 HARLEY DAVIDSON FLTRI
1999 - 2003 HARLEY DAVIDSON FLHPI
1999 - 2000 HARLEY DAVIDSON FLHP
1999 - 2000 HARLEY DAVIDSON FLHPE
1999 - 2003 HARLEY DAVIDSON FLHPEI
1999 - 2000 HARLEY DAVIDSON FLTRSEI
2001 HARLEY DAVIDSON FLTRSEI-2
UNits affected:    81496
Recall Number:    04V134000
Summary:    ON CERTAIN TOURING AND POLICE MODEL MOTORCYCLES, THE 40 AMP MAIN CIRCUIT BREAKER CAN ¬OPEN¬ FOR REASONS OTHER THAN WHICH IT WAS DESIGNED, CAUSING AN UNEXPECTED INTERRUPTION OF ALL ELECTRICAL POWER TO THE MOTORCYCLE.
Consequence:    THIS CONDITION COULD CAUSE THE MOTORCYCLE TO STALL, WHICH COULD RESULT IN A CRASH.
Remedy:    DEALERS WILL REPLACE THE CIRCUIT BREAKER. OWNER NOTIFICATION BEGAN APRIL 23, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.
Notes:    HARLEY-DAVIDSON RECALL NO. 0113.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION¬S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

I was amazed that this wasn't caught when I have the bike inspected prior to purchase as the recall was outstanding for this particular unit.

Problem solved, I hope.     Martyn

[harleyjt]

Thank you both for your interest in my problem.

After a few hours digging around on-line, I looked up recalls. It appears that in 2004, there was a recall (04V134000) for my bike.

I've pasted below the recall:

Build Years/Makes/Models:    1999 - 2003 HARLEY DAVIDSON FLHTCI
1999 - 2003 HARLEY DAVIDSON FLHTCUI
1999 - 2003 HARLEY DAVIDSON FLHTPI
1999 - 2003 HARLEY DAVIDSON FLTRI
1999 - 2003 HARLEY DAVIDSON FLHPI
1999 - 2000 HARLEY DAVIDSON FLHP
1999 - 2000 HARLEY DAVIDSON FLHPE
1999 - 2003 HARLEY DAVIDSON FLHPEI
1999 - 2000 HARLEY DAVIDSON FLTRSEI
2001 HARLEY DAVIDSON FLTRSEI-2
UNits affected:    81496
Recall Number:    04V134000
Summary:    ON CERTAIN TOURING AND POLICE MODEL MOTORCYCLES, THE 40 AMP MAIN CIRCUIT BREAKER CAN ¬OPEN¬ FOR REASONS OTHER THAN WHICH IT WAS DESIGNED, CAUSING AN UNEXPECTED INTERRUPTION OF ALL ELECTRICAL POWER TO THE MOTORCYCLE.
Consequence:    THIS CONDITION COULD CAUSE THE MOTORCYCLE TO STALL, WHICH COULD RESULT IN A CRASH.
Remedy:    DEALERS WILL REPLACE THE CIRCUIT BREAKER. OWNER NOTIFICATION BEGAN APRIL 23, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.
Notes:    HARLEY-DAVIDSON RECALL NO. 0113.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION¬S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

I was amazed that this wasn't caught when I have the bike inspected prior to purchase as the recall was outstanding for this particular unit.

Problem solved, I hope.     Martyn

Glad you found the recall.  Not sure why it took you hours looking for it when I gave you a link above.  Anyway, I feel reasonably certain that is your problem.   
jt

[Mulsanne]

Hi JT .....thanks for the info. The posting must have crossed with my search, but thanks to everyones input.

I'm a little amazed that it wasn't picked up by the dealer, in fact two dealers, both couldn't shed any light on the issue at all.

I have switched out the breaker and will keep you updated.

Thank you again.  Martyn