This issue was a nightmare for a riding buddy of mine. Replaced 3 times and still kept overheating and popping breaker. The final fix was rerouting the breaker further back on the bike. Not only did the breaker have to be changed out, but the terminals that attach to it were deemed inferior and was supposedly the reason for the heat. After it was finally fixed he never had another issue with bike.

 

Where did he move the breaker to? I'm still having the problem when it gets real hot.

 

I ride the 2003 anniversary ultra. Stator and regulator went at 35k (happens to a lot of bikes). Just did the cam chain tensioners at 50k (replaced with hydraulic type). The fork oil is good to 50k, and it is a pain because of the cartridge on one side (forks have to be removed and disassembled to change oil). Great bike, no real issues that others don't have.

 

yep the rear injector wire will break and maybe a few other wires, the whole harness was real tight...hd engineering sucks

 

In-tank fuel line will rub on the tunnel and develop pinholes. They came out with a shorter fuel line in late '04 to fix that problem.
AP

 

Pretty sure he extended to under tour pak. I'll double check w/him later today tho.

 

I have an 03 and I must agree with the comments so far. The bike over heated and blew breakers, but there was an up grade that fixed it for no charge, I changed to cam drive around 20K, so that was not a problem. oil change in the front forks is part of the 40K service. Stator went out about 48K, but all in all the bike has been a good dependable ride, a lot better than my friends 05 he has been through 3 motors

 

My 03 has 75K plus miles, stator @ 50K is the only big deal. When I rebuilt the engine this year it was still running great, very little oil burn. I just wanted a "Hot Rod". We did find the inner chain guide had a piece broke off and scarred the oil pump at some point (outer looked great). I didn't care as I was putting gear drive and new pump on anyway. I did not own the bike during the first 50K so I don't know what had been done to it.

 

fork oil and brake fluid IMHO