OK, This is a very common problem. Mine did it last year at Sturgis. I talked to a Harley engineer who was at the dealer helping out. There is a problem with the crimps and lugs on the wires going to the circuit breaker. They had a kit and repaired it on the spot. The weak crimp and lugs creates a high resistance connection and creats a lot of heat causing the circuit breaker to trip. They cut the ends off and replaced them and re-crimped the new ones. Harley has a little fix it kit for this and according to the engineer, Harley is aware of the problem. Mine has not cut out in over 15,000 miles since being repaired, so I do believe this was the culprit. I hope this takes care of it for you.
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Electrical Problem - '03 Ultra Classic
- Thread starter :)Gabby(:
- Start date
ThePolicestoleMyCar
New member
Wow, good info!
Thanks for the reply. I now know what you are talking about. I replaced the 40 amp with a 50 amp (twice). I also replaced the 2 relays you talked about on the left side of the battery (I forgot all about that). The ignition switch is the only thingI didn't replace. If yours is like mine it's made out of plastic. I fiddled with it and it didn't seem discolored or smell burny, but as you say, it may be worth a try. In terms of my bike, I've gone as much as 700 miles in a day and it never cut out, or as little as 10 miles and it started happening. Frustrating to say the least.
Once again, thanks and if you have anything else to offer, just drop me a note. I'l also keep you posted
Once again, thanks and if you have anything else to offer, just drop me a note. I'l also keep you posted
Well the main CB (circuit breaker) under seat and in front of the battery is what I believe you're referring too.
It opens up to protect the main wiring harness when there is too much of an electrical draw.
The draw is caused by a direct short to ground or a short across two wires, one of which is going to ground.
You say all grounds have been rechecked.
It only does it while riding.
You say it will restart after it cools down.
I know it's a pain but try this.
Get a GOOD quality toggle switch and some wire and 2 alligator clips.
Remove the seat and hook this setup across the two terminals of the 50 amp CB (above). turn the switch off and let it hang out where you can reach it while riding.
Next time bike dies, try to restart bike if it doesn't turn switch on and try a restart again. If it now restarts it is definitely the circuit breaker.
It has been overloaded with current draw. Turn the toggle off and wait for CB to cool down and restart and drive home.
somewhere in the main ignition circuit you are drawing too much current.
since everything else has apparently been checked.
I would pull the starter and have it checked.
sounds like it is starting to short to ground.
Could be a couple other things too.
Now when bike dies if ALL the other electrical is working and bike will crank but not start I would check the crank sensor and the bank angle sensor.
this sensor is located in the turn signal module. Could be bad, bad connection or not seated properly.
These are just a couple ideas.
It opens up to protect the main wiring harness when there is too much of an electrical draw.
The draw is caused by a direct short to ground or a short across two wires, one of which is going to ground.
You say all grounds have been rechecked.
It only does it while riding.
You say it will restart after it cools down.
I know it's a pain but try this.
Get a GOOD quality toggle switch and some wire and 2 alligator clips.
Remove the seat and hook this setup across the two terminals of the 50 amp CB (above). turn the switch off and let it hang out where you can reach it while riding.
Next time bike dies, try to restart bike if it doesn't turn switch on and try a restart again. If it now restarts it is definitely the circuit breaker.
It has been overloaded with current draw. Turn the toggle off and wait for CB to cool down and restart and drive home.
somewhere in the main ignition circuit you are drawing too much current.
since everything else has apparently been checked.
I would pull the starter and have it checked.
sounds like it is starting to short to ground.
Could be a couple other things too.
Now when bike dies if ALL the other electrical is working and bike will crank but not start I would check the crank sensor and the bank angle sensor.
this sensor is located in the turn signal module. Could be bad, bad connection or not seated properly.
These are just a couple ideas.
Santino WwE~4~LyFE
New member
I'd add a fuse of some kind in there just in case you have a dead short!! You can fry a lot of wires or electricals in a very brief moment!
My '03 UC did the same exact thing 3-4 times in about a week or so, even AFTER the 50 AMP recall. I re-did the crimp like was mentioned, (I did it myself rather than use the HD fix because I know what my work is like!) and it hasn't happened since. That was beginning of riding season last year and probably 10,000 miles ago. I'm pretty anal about things like this so I cut the ends of the wire at the old terminal to get good, fresh wires under the new, heavier terminal. I soldered them together (well) and replaced the 50A breaker with a new BUSS brand one, I did both wires going to the breaker and I bought all the stuff at O'Reilly Auto Parts (shameless plug....). Good luck!
My '03 UC did the same exact thing 3-4 times in about a week or so, even AFTER the 50 AMP recall. I re-did the crimp like was mentioned, (I did it myself rather than use the HD fix because I know what my work is like!) and it hasn't happened since. That was beginning of riding season last year and probably 10,000 miles ago. I'm pretty anal about things like this so I cut the ends of the wire at the old terminal to get good, fresh wires under the new, heavier terminal. I soldered them together (well) and replaced the 50A breaker with a new BUSS brand one, I did both wires going to the breaker and I bought all the stuff at O'Reilly Auto Parts (shameless plug....). Good luck!
First, I would like to thank everyone that's responded to my posting regarding the electrical problem I have with my 03 Ultra Classic. A number of you have experienced what appears to be the exact problem. While this is comforting I am at a loss why I never heard anything about it from HD until I posted it on the HD Forum. A number of you made reference to the breaker being upgraded to a 50 amp from a 40 amp. I never received a Recall on it and it was only when I started having electrical problems wasI made aware of the increase in the amperage by a HD shop. I can't understand why something that can have potentially fatal consequences (total elctrical failure resulting in engine cutting out while passing / total loss of electrical, resulting in loss of all lighting at night) was not brought to my attention by HDbefore I started having serious electrical problems. I am registerd with HD, asI bought my bike new. I also now question whether increasing the breaker from 40 amp to 50 amp was just a "Bandaid" solution, as it apppears the root problem for a number of people had to do withwhat they report as sub-standard wiring connections (creating enough heat for the main breaker to trip).
I made contact with the Canadian disributor for HD this past Friday and while he did not acknowledge or seem aware of any systemic electrical issues with the '03 UC, he told me the local HD shop would be in contact with me in the next while and once they've inspected my bike, would be instructed to contact the HD technical group (I guess my problem is now registered). The fist time I reported it to the Canadian distributor for HD in early October, he just told me to take it to the local HD shop despite the fact that I've already had it into 2 seperate HD shops.
If there are others who have had a similar problem to the one I posted I would appreciate hearing from you. Once again, thank you for your help.
I made contact with the Canadian disributor for HD this past Friday and while he did not acknowledge or seem aware of any systemic electrical issues with the '03 UC, he told me the local HD shop would be in contact with me in the next while and once they've inspected my bike, would be instructed to contact the HD technical group (I guess my problem is now registered). The fist time I reported it to the Canadian distributor for HD in early October, he just told me to take it to the local HD shop despite the fact that I've already had it into 2 seperate HD shops.
If there are others who have had a similar problem to the one I posted I would appreciate hearing from you. Once again, thank you for your help.
nope.....i just had the exact same prob on a fiends bike......and i mean exat as you describe.......its your ignition coil....its bad and breaking down the CB is doing its job...when it draws excess current it opens because of the windings in coil shorting together.......we chased that dang thing for month and finally found it .....replace the coil......then ride the heck out of it..............im so sure i will bet beer on this one!!!!!