2005 Heritage Softail Classic FLSTCI-Electrical Issue

[MAllen7424]

I have owned this bike since new, So far never broke down riding accross country US in the beginning the bike kept intermittantly blowing running lights fuse. Taken to Service in NJ they claimed they fixed it by replacing horn and front fender wiring harness. huh? ok?... Took bike back 15 minutes later for break light issues...came back fixed....hooray! ...so I thought. Kudos for Edison Harley-Davidson in Highland Park NJ for at least tried to fix and find problem.

Odometer reading (8600) Road trip 3200 miles accross country first 500 miles Passing light blows out... oh well s!@# happens and s!@# breaks! Get to St.Charles, MO for 10,000 service finding out the passing lamps are obsolete. Need to replace Passing Lamps lights and new housings out of my pocket for Harley-Davidson's mistake for lowest bidder parts on a new bike. I never changed them because they would have to order parts....no time... back to road trip.... next 500 miles other passing lamp blows out. oh well inferior parts!

Now I arrive in Seattle WA in the rain being stopped by a motorist because I have no brake lights at all. Bulb replacement... oh well was a long ride. During my time here on the west coast I had nothing but problems with bulbs blowing out in the running lights and brake light...well I did do alot of riding so it was time WA Sound 15,000 maintainance. Front fender light out (known issue because all it does is blow out all the time intermittenly... got tired of replacing so left it out) Service Dept claims I have a electrical problem after I already gave story of known issues and past issues during check-in of the bike for maintainance. 15,000 maintainence done and service didn't even bother to fix electrical known problem and says front fender bulb keeps blowing!...they cant find the problem, they recommend to bring bike back to Service dealer in NJ that first worked on electrical system under warranty...uhmmm hello!!!... I am over 3,000 miles away from there riding the motorcycle! oh but wait they did find the brake-light switch at foot brake pedal not functioning... $100.00 later(fixed) .... My 1984 chevy with 350,000 miles on it still has its original brake pedal switch uuugh!... So now I have to ride back to east coast with an unidentified electrical problem. Anyone have any troubleshooting techniques before I hit the road with this electrical issue that now I have to fix myself because the service dealers can't obviously fix it.

Oh and I must thank Sound Harley-Davidson Marysville, Washington for tightening my seats THUMB screws so tight that I had to pull out extreme tools to get under my seat. Thank god I had a big enough screw driver to get them loose if I was on the road I would have been literally screwed without a large screwdriver. Yeah I checked everything again after they work on it...those mechanics probably think its funny that they did this.. I don't think so!!! Almost as bad as (1000mi. maintainance) Liberty Harley-Davidson in Rahway, New Jersey for Lock-tite-ing and Teflon taping my drain plugs with the red Lock-tite and boy were those poor mechanics upset when they tried for 2 hours loosening them at Harley Davidson service (5000mi. maintainance) in Fremont, Nebraska with leveraging bars on the bench 100.00 bucks later.

Oh and also thanks for the new scratches on my windshield, I told you NOT to wash my bike!


Still riding with no passing lamps on a fairly NEW motorcycle because of obsolete parts and electrical problems.


Thanks in advance

-UnSatisfied Harley Owner

My butt hurts and I haven't even left to go home yet! and I still haven't got a free T-shirt!

[SCHMIDTYS]

Ok ... so it sounds like you're on the road and don't have time to intro yourself .
Are there any CODES ? Engine light on or comes back on after the engine is started ?
If no codes then the problem is outside of the engine management system , if there are codes then it's in the EMS . This info would be usefull .
If you make it as far as Wisconsin and still are having problems contact me and I might be able to help out .

[MAllen7424]

Thanks Schmidtys for the reply,

I apologize for my frustration, knowingly having these issues on the road with limited tools does not make my ride pleasant when I know that anytime something can go wrong that should have been fixed in the first place. No one mentioned any error codes and the engine light has never turned on reporting engine issues. It seems to be in the light wiring like a gremlin back and forth from the front fender light to the brake light. I am with limited tools now. I am to the point from my unsatisfied experiences with certain Service shops to even let someone touch the first piece of machinery I ever owned NEW. They treat me 'the customer' like gold but when it comes to the bike they treat it like a wet food stamp especially when I try to baby the thing and keep it showroom quality. Only reason I am still riding or should I say taking a chance on the road because I am praying it is only an issue with just the light wiring and not interfering with EFI and motor functioning. I am running out of time for departure. Running I5, I90, 84, I80 home.

Thank you, I have been in every state in the US but 5 states, WI being one of the five. I really have no intention to go there hahaha. You can just make me feel better by telling me its not going to short out my EFI while on the road. I am already low on funds because of our wonderful economy.

-Mark

[SCHMIDTYS]

Ok ... if the engine light isn't on constantly you don't have a current code . If the light comes back on after going out there is a stored historic code but is not an issue . The engine light staying on constant could be trouble as that is the EMS .
If all the turn signal lights flash after turning on the ignition then there is a problem with the TSM or the lights / wiring .
Having had your bike to so many HD shops I'm assuming that the problem isn't apparent BUT ... I would look at the wiring inside the front and rear fenders to verify that the tires haven't rubbed through the wires for some reason .
The brake light isn't tied in with any of the other lights except through the wire harness in the rear fender and under the seat and up to the front brake control in the switch housing . Sometimes wires get pinched at the switch housing when custom grips are installed .
Obviously there are many areas that could cause problems with the symptoms you're describing .
Good luck and keep us posted on your trip .

[MAllen7424]

Thank you for your expertise and love of motorcycles SCHMIDTYS,

I haven't experienced any codes at all in my travels. Everything on my motorcycle is Stock from factory so I wish I can say it was user error and my fault. Then I would take full accountability of the short and stop debating my frustrations with the poor mechanics and service representatives. I will keep you up to date in my status when I arrive in NJ. I am not a casual rider, I am an extreme traveler, I will be home in 5-6 days after departure from WA. I just like to have lights to protect me in the dark and possible rain. I will be spending 2 days in Omaha, NE area maybe I will get a opportunity to check in here to say hello.

Once again thank you, I will be holding my breath and will be trying not to smile on my ride those bugs don't taste very good.

-Mark