I have a 2001 Ultra Classic that keeps shutting down randomly. I've had it to 5 dealers and Indy shops, have left it for them to ride for weeks at a time, put on a Dyno under stress etc. Mechanics can't seem to find problem. Going along fine then all of the sudden it will just quit, no electrical, then almost as fast it will come back to life.

I've crimped every wire and spade connector, changed every relay, upgraded the circuit breaker and ignition wire, I don't know what else to look for nor do any of the mechanics that have worked on it.

It seems to be heat related, but I'm not positive.

Any of you seen this before and know of a cure?

Thanks,

I know my signature says 99 Ultra...I have both.

 

I had a bike in the shop that did that at one time as well, there was a recall on the ciruit breakers, but you said you did that, we also found a very small crack on one of the wires that came from the voltage regulator to the startor so we replaced that and it seemed fine afterwards? My thoughts of the time were possibly that under the right circumstances that it could short out on the frame and make the ECM do somthing funky? Just check all your wires that run along the frame for possible case cracks that could cause a short?

 

Mine did the same thing. My CB was replaced on the recall a couple of years ago so I didnt think it was that but it was the cheapest so I changed it anyway and it hasnt shut down since. I think the 50amp CB was only around 6 bucks and easy to change.

 

Sounds like the electrical needs to be checked as soon as the problem occurs.

 

Well these intermittent problems can drive you crazy.
try this as a possible,
Unplug the harness to ignition switch.
Fabricate a jumper wire. Jumper the harness (bypassing the switch).
Make sure the jumper wire is same wire size as harness, I think 10 gauge.
Ride it and see if problem goes away.
some of the 98-01 bikes had a TSB on a load eliminator to be installed on
the ignition switch. Load eliminator rerouted some of the heavier current draws
around the switch. The switch was being overloaded and opening up from the heat
causing the electrical to shut down.

You state when the problem occurs you lose all ELECTRICAL.
so makes sense to look at the electrical circuit itself.
You already checked most everything else.
You could have a main power relay failing or corroded or faulty connection
But you said you replaced them.
but I would check the ignition switch first. HD sells a switch load eliminator.

 

Check the Main Overlay Harness, specifically the area right in front of the tank where it attaches to the left side of the framebefore going into the fairing. Some bikes, including my '01 Ultra, have had broken wires INSIDE the harness right right in that area. Mine was a broken VSS wire that made the speedo fluctate intermittantly. The dealer could not find it, so I took it to an Indy, and they traced it and found it. Another rider had a broken cruise control wire. Could be yours is an ignition wire.

Let us know what you find.

 

Thank you gentlemen, I will try those ideas and let you know.