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  #21  
Old 19th July 2007
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Thanks to all for this information. This has been good reading and like someone said , I bet there have been a lot of other "electrical" problems that have occured to others that probably can be related to washing. I'm going to look at my wiring harness and do some waterproofing.
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  #22  
Old 19th July 2007
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After doing some work on the bike today, i am fairly convinced that my theory is right.

My "oxidation trail" was on the system relay going from the "E" terminal ( UN-SWITCHED BATTERY POWER ) to the "K" ( Fuel pump, ejectors, coil, and ECM ) and "U" ( kill switch on bars, and ECM ) terminals.

Obviously, if the oxidation between the E and K was the cause, the fuel pump would be priming at some point, so the possibility of this being the cause was unlikely unless the pump was to much for the stray voltage path theory as i mentioned in the post above.

I believe that the stray voltage was going from E to U. The only question was why wasn't supplying voltage to the kill switch ( from the "back side" ) causing the relay to trip when the kill switch was in the run position. You see, one side of the electromagnetic field coil in the relay comes from the kill switch ( when in "run" ), the other from a terminal marked "system relay" in wiring diagrams. Not having the electronics service manual, i was under the mistaken belief that this terminal on the ECM supplied power to the system relay. Now i know that it simply monitors the relay to see if it's working.
I found this out by jumping the terminals from E to U. The bike sat there, and made the same rhythmic cycling of the IAC motor that had first gotten my attention. No lights, or other indications as to what was going on: just the IAC cycling.

The confirmation that the ECM terminal marked "System relay" was for monitoring purposes came in the form of a check engine light and subsequent trouble codes pertaining to the injectors and system relay after the bike was restarted. This was caused by the fact that i had turned the ignition on with the system relay pulled out during my trouble-shooting. Those codes, by the way, were found in the "sticky" elsewhere on this board. What a great tool this place is.

I proceeded to clean the entire fuse/relays and block(s), and pack everything with Dielectric grease, which should keep the corrosion at bay.

My bike has been acting normal since i "tapped" the relay several days ago. Only time will tell if this is the true cause, but i think it is. Honestly, i am appalled at the amount of corrosion present in the fuse/relay panel of a barley-two-month-old bike that's never even been ridden in the rain. This cycling of the IAC ( which some have describe as a "purring like a cat" sound ) could certainly cause the dead battery problems several have been reporting. Then consider how many people are getting dead batteries or noise right after they wash the bike.....

I suggest you check your fuse block even if you arent having problems.

I also fully expect service bulletins about this to start appearing soon.

Good luck.
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  #23  
Old 19th July 2007
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I wonder if this has any relation to the fuel pump issues we have been seeing with some of the new sportsters?
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  #24  
Old 21st July 2007
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dg i have had the same exact thing on my 07.
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  #25  
Old 21st July 2007
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the dealer cant figure it out. i will bring it to thier attention. thanx
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  #26  
Old 21st July 2007
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I made this thread a "sticky" because it seems to be a common issue..
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  #27  
Old 24th July 2007
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I have never had this problem, but I have a partial solution. If indeed the electrical problems are post-washing problems and water/oxidation on the fuse block, you should pull down the side cover after every washing and thouroughly dry that area. What I have been doing for many years on every bike I have owned is dry the bike down with compressed air after washing. Very similar to those pricey cycle air dryers ($300!!!) or you can even use a leaf blower. I make sure I blow out all the electrical connectors, fuse block, and battery terminals, everything. No waterspots either!!! Good luck.
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Old 27th July 2007
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DG and Danoman,
I had the same issue with my 07. I rode the bike through the winter rain and in the spring the battery died. After numerous unsuccessful attempt by the dealer to correct the problem this is what happened. A relay was badly corroded on the outside, and cutting it open revealed the corrosion has made it's way inside. Replaced the relay and everything is fine.
One thing I noticed during this was a mechanical sound coming on from behind the air cleaner intermittently.
I agree with DG that the fuse box is insufficiently protected from the elements. Any vehicle should be capable of keeping it's electrical system protected.

My most recent warranty issue is oil leaking from the rear rocker cover, and both cylinders. sound familiar to any 07 owners?
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  #29  
Old 27th July 2007
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How many miles on the bike?
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  #30  
Old 27th July 2007
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Default Here Is The Answer

TT322 – July 26, 2007 - 2007 XL Models with Discharged Batteries or Very Low Voltage 2007 XL Models with Discharged Batteries or Very Low Voltage

Harley-Davidson has found some ’07 Sportsters where the batteries are going dead after a night of sitting. The root cause is water intrusion. Water can run down the harness, funnel into the fuse block area, and then bridge the system relay contacts. The system relay has constant power available on the 30 terminal.
When the system relay is activated, power goes to the ECM, and then the ECM sends power out to the IAC. The IAC will then run until the battery is fully discharged.
To prevent this issue, Electrical Contact Lubricant (p/n 99861-02) can be placed on the terminals and base of the system relay, and the receptacles at the fuse block. This will create a water barrier once the relay is installed into the fuse
block.
Motorcycles exhibiting this condition could also have corrosion present, and if necessary, should have the relay terminals and receptacles cleaned with a wire brush or replaced.
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