Circuit Breaker

I have recently purchased an 2003 ultra classic and have a problem, the bike’s main circuit breaker will open up and completely shut down the bike every time I ride. There was a breaker recall on this model and I have had it change by the dealer twice and I’m still having the same problem, they have been unable to find anything causing this trouble. Some history on the bike is as follows, the top end has been changed to a 95cu screamin eagle and the cam chains have been replace to a gear drive, this is a EFI model and the only other things that come to mind that are not stock is it has a Barnett scorpion clutch and some led lighting installed in the tour pak and the saddle bad tops, can you help? I have you DVD’s 1 and 2 touring and the performance DVD, thanks, Roger

The main breakers amperage rating is set with a totally stock motorcycle. Start by removing the fuses that control the lighting , then ride the m/c and see if the breaker trips. If it does not you have over loaded the rating of the stock breaker, replace it with a breaker 5 amps higher and try that. You can try removing fuses one at a time as long as they do not effect the f/inj or ignition. I have also had charging overload the breaker on the return voltage side, you can unplug the voltage regulator and see the results, just don’t ride too far (no more than 15 miles).

 

Wrench Safe,

Team FMH

Customer follow-up: Thanks so much for your response to my issue with the bike. The dealer I’ve been using has finally called a factory tech and they are telling the dealer tech that they have had some problems with this in the past. The issue is in the terminal ends at the breaker, some of the aluminum terminal ends in the past have had some issues with to much resistance, therefore the higher the resistance the more heat is generated with normal current flow, I sure hope this corrects the problem, the factory is sending out some different terminal ends for the wiring at the breaker. Thanks, so much for reply