Yes, this has been occurring since the bike was new, although fairly infrequently back then. The HD dealer was never able to get the problem isolated, identified & corrected under the MFG warranty but that is a different topic and conversation for another time. Unfortunately frequency has greatly increased to become very problematic and dangerous. Idle setting was adjusted. Again, it has never thrown an error code upon occurrence.

 

Thanks for your ideas on potential problems and solutions. "To date" I have been unable to identify & fix the problem. I am unwilling to simply throw $'s at the problem as that is an expensive game to play, and not very efficient. Any other ideas, experience or perspective anyone has would be greatly appreciated as the dealer has been of limited assistance as the problem is intermittent and does not generate error codes.

 

My 03 also had the 40 to 50A recall done but it still had the problem. The issue is that you lose power for just a second while the circuit breaker trips off, and then it resets. Your symptoms are the exact same as mine, and the problem became more problematic over time. The fix is under $10 and only takes about an hour of your time. One way to see if this might be your problem is get the bike hot while at idle, see if you can replicate the problem, and then turn off all extra electrical items (stereo, spotlights, cruise, etc) and see if the bike loses power after you do that. The combination heat and power draw is what kicks the circuit breaker off for that second. The other issue is that corrosion builds up on the terminals to the circuit breaker and in the crimps. Removing that corrosion from the terminals when you replace the circuit breaker with the inline fuse solves that issue. An hour of your time and under $10 and I bet it fixes your problem. I didn't believe this was the issue with mine but ultimately it was.

 

I wanted to wait until I was certain I had determined the true problem, the proper fix, and tested it. It turns out the problem was "thin" connector wire ends on the wires running through the main circuit breaker. Being too thin & under load they would heat up and trip the main circuit breaker. By cutting, cleaning, and reapplying new connector wire ends a problem that has been present on this bike since it was brand new from the factory has disappeared. The connectors did not visually look too "thin", dirty, or have any corrosion on them. To my surprise HD in Milwaukee has been aware of this problem for years and quietly communicating the remedy to those dealerships who inquire. Amazing the number of hours, $'s and frustration chasing a 6 cent solution. Thanks to everyone, and Hx3 who assisted me as it was a post on this forum that lead to the solution.

 

had the same issue with my 03, saw the recall and solution from hd on this forum. When I went to replace my breaker, I dicovered that the factory crimp on the terminal for the breaker was the fault. The insulation was not stripped prior to crimp and just crimped thru the insulation. The heat shrink covered the error. I replaced the terminal, didnt replace the breaker and never had another issue