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TT322 – July 26, 2007 - 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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Linear Mode
