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Thread: Sportsters: Fuses Blown, Battery Dead, Water Intrusion Damage...!!

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    Sportsters: Fuses Blown, Battery Dead, Water Intrusion Damage...!!

    Quote Originally Posted by phil View Post
    this is a known issue. It is the subject of harley tech tip 322, from july 07.

    Make sure that your dealer has covered the repair as detailed.
    Factory Bulletin pdf below.
    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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    Last edited by BaZa; 27-08-2012 at 08:19 PM.
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