KKiley, I'm wanting to know more of the fault you experienced re your TSM. The fault I have is only activated by accellerating hard (fast twist of throttle) and letting the rev's get above 4,000 RPM. Once the fault is present my decel (de-accelleration) is dead. However, if when in decel I flick the starter switch off/on everything returns to normal.

A close friend of mine (a local HD tech) first thought was my TSM/TSSM bank sensor (accellerometer) may be playing up from either water or it's connection may be loose. He recommended I put my old TSM in to see if anything changes...I've not had a chance to do this yet.

 

A TPS will cause the issue, it may test good but not working correctly. For me it would be worth it to change it out to see one way or the other. Testing sensors sometimes won't find a faulty one I've seen to many test good and be bad. JMO

 

I've since cleaned and greased as many electrical plugs I was able to reach and the dead decel became intermittent, still with no DTC being present...However, my security key was indicating that a historic code was present but with no codes and was only able to cleared by following turn signal DTC procedures which in reality the procedures aren't for 2004 FLSTCI. Now a couple of weeks later and many additional miles clocked up my dead decel fault is non-existent but I now finally being presented with a DTC through the speedo 'U1255' which indicates there is a communication problem between the Speedo, TMax & TSSM. I'm installing a new starter shortly and will therefore have access to areas I need to check. I still feel it was a water problem with my TSSM, i.e. at first something full of water causing the fault, then condensation causing it to be intermittent, and now dry the fault is gone.

 

Ridden a couple of long rides since and now even the DTC-U1255 doesn't exist. I'm so much looking forward to going over all my electrical wires and parts in an attempt to find the culprit. Never want to experience this again...I'll have no hair left if it does. About time I put another bell on my bike.

 

I'm confident that I finally found my gremlin...

Over the weekend I installed a heavy duty starter motor and in the process I went over all electrical parts and greased all electrical plugs behind the oil tank. When removing the main circuit breaker to access the small oil tank bolts the breaker fell apart in my hands and the tin cover had mud it in...Evidence of once having water trapped inside. Everything else looks fine.

On assembly I'll also be checking out my RH handlebar controls - switches.

 

You sure have been working hard. Good job having the patience it takes.

If it had been a fused device you probably could have found it when it popped. Breakers resetting are hard to pinpoint unless they fall apart in your hand.

I hope this brings a conclusion to you issues.

 

Thanks guys but I don't think a circut breaker would have caused my problem, if it was this the whole bike would shut down once the fault was activated. I still can't explain why the fault when first experienced would only activate when twisting full throttle and allowing the engine to rev to 4,000 rpm...the engine would still run and rev to the limiter but the decell was dead until I switched the engine off & on again...I could ride the bike all day with the fault present but only the decell being dead. However, if I twisted the throttle slow and easy the engine would rev to the rev limter without activating the fault.

I'm glad this has all gone now and that water was the cause but it would be nice to find what water had got into to have caused it, as I don't want it back again.

Late yesterday afternoon I stumbled across a wire that had been rubbing on my oil tank, just ware and tare after 7 years of rubbing. It had warn through to bare wires and would explain why I wasn't holding a full charge, the battery losing power when left parked up for longer than a week, if not left on a trickle charge.

My HD Mech still claims that something may be wrong with my TSSM and could have had water in it and now that it's dry everything is back to nomal. He wants me to put my original TSM back in but with not having the fault present I'll never know if it was the cause, and I don't what the bike unarmed when left out.

I still intend to inspect my RH controls as I know there is a suspect wire inside...a while ago I had to do some urgent repairs and the quick mend done may have come adrift...but this still wouldn't explain why fault activated at 4,000 rpm and only if holding full throttle.

Will keep you informed as I find more and what I find in the RH controls...glad we've rotten weather at the moment because not being out on the road is killing me.

 

I'll throw in my 2 cents for what its worth. I had the same type of problem on my '02 Road King Classic also equipped with the Thundermax with autotune. Would intermittently cutoff in high rpms and had to reset switch as you do. After being reamed by Harley dealer who could not find the problem I decided to buy a new throttle position sensor EVEN THOUGH DEALER SAID IT WAS GOOD and my problem went away. It drove me nutty for awhile like the exwife but we can't divorce our bike so I persisted until fixed. I hope you'll find the cure soon! The Tuscorora Chief!

 

And it is a cheep sensor! Maybe a 20 min job.

 

-->TuscororaChief . . . .I had the same type of problem on my '02 Road King Classic also equipped with the Thundermax with autotune. Would intermittently cutoff in high rpms and had to reset switch as you do. . . . . I decided to buy a new throttle position sensor EVEN THOUGH DEALER SAID IT WAS GOOD and my problem went away. . . . . . <--

-->Blk and Chrome A TPS will cause the issue, it may test good but not working correctly. . . . . <--

-->soft 02 Tps?..Doesnt set a code and will test good if it has water in. This has happened to me. Good luck<--

Jamesn if TuscororaChief and Blk & Chrome both had "intermittent" TPS sensor issues and especially since Soft02 says it ain't much money, I'd definitely replace that sensor just to see if it's the culprit.

ThunderMax relies even more on the TPS and RPMs than Delphi does, since the TM doensn't utilitze the MAP sensor. I don't know how water proof these TPS sensors are mounted, since you said you had previously washed the bike. But in any case these guys solved the same issue with a TPS replacement, sounds like a good thing to try.