Electrical Meltdown

Helpful hints for making the most of your XR along with combined knowledge and remedies for common faults
molymax
Posts: 3
Joined: Sat Jan 23, 2021 1:08 pm

Electrical Meltdown

Postby molymax » Tue Feb 16, 2021 11:05 am

I bought my XR new in 2009 and since then have put about 38k miles on it. Its been a great bike with very few niggles until now. Over the last couple of years, regulators & batteries have been changed due to the engine warning system throwing up fault codes. The problem I have encountered can best be explained as follows:
DTC’s prior to last trip to the mechanic:

P0563 – Part # 32164-08A Displayed when battery voltage is greater than 15.0 volts for more than 4 seconds.
B0563 – Part # 68924-07 Module Security System If the voltage exceeds 16.0 volts for more than 5 seconds the TSM/HFSM sets B0563
B1006 – Part # 67087-08 Speedometer is displayed when accessory line voltage is greater than 16 volts for longer than 5 seconds
B1007 – Part # 67576-08 Tachometer as above but ignition line voltage.

Engine warning light would come on intermittently and instrument backlight would come on and go off. Usually the bike would start ok (from cold) and run perfectly for up to 10-15 minutes before starting to miss and backfire with the engine warning light flashing on & off. Does this suggest a thermal issue with the electrics?
During the diagnostic evaluation the mechanic could see “spikes” of approximately 15-16 volts but they were of very short duration. Further inspection failed to identify how these “spikes” were occurring. Tests of the stator did not show a problem and I had fitted a brand-new regulator. A new Lithium battery was recommended as it can handle power spikes better than the AGM equivalent.
Prior to the bike finally failing; the mechanic test-rode the bike for a local journey (no problems were observed) before I rode it home. Initially it rode perfectly but after 10 minutes or so the above issues started and it finally stopped running. Back at the dealer the above damage was noted*.

Prior to going to the mechanic, the bike had it’s third regulator/rectifier fitted and had a brand-new Lithium battery fitted by the mechanic having fried 3 previous batteries. The bike is now a non-runner and will need transporting to a dealer if a repair is considered viable. Does anybody know of a Harley electrical specialist who could look into and hopefully solve this issue? I really need someone who actually knows what they are talking about[/.
Damage so far: Fried Electrics – melted TSSM Module, blown lightbulbs, No ECM signal, Tach & Speedo not working.
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Compo
Posts: 438
Joined: Sat Mar 12, 2016 2:04 pm
Location: Yorkshire

Re: Electrical Meltdown

Postby Compo » Wed Feb 17, 2021 7:00 pm

Hi

I have had electrical problems on my XR

They are very simple bikes but are getting on a bit now.

I'll have a think about your symptoms, where abouts are you?
I'm not racist, I'll race anyone!
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Rob_Wakey
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Joined: Wed Mar 09, 2016 6:45 am
Location: Wakefield West Yorks

Re: Electrical Meltdown

Postby Rob_Wakey » Sat Feb 20, 2021 10:33 pm

Try going on the Facebook XR group or failing that the US site as there is a bigger knowledge base.

If it hadn’t been from the frequent regulator changes that’s what I’d have thought with the spikes or maybe the coils failing under load.
After me you're first :twisted:
molymax
Posts: 3
Joined: Sat Jan 23, 2021 1:08 pm

Re: Electrical Meltdown

Postby molymax » Mon Feb 22, 2021 9:52 am

Thanks for the replies. I'll take a look at the FB page. I am in deepest Essex so if anybody knows a specialist down this way who genuinely knows what they are talking about with electrics / fuel injection, I would be keen to make contact.
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Rob_Wakey
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Joined: Wed Mar 09, 2016 6:45 am
Location: Wakefield West Yorks

Re: Electrical Meltdown

Postby Rob_Wakey » Tue Feb 23, 2021 8:12 am

Look up V-Twin custom in Rye, one of the guys there, Boz, is a HD guru and is well known for XR tuning, EFI, etc. . . . He does articles in the American V mag. . .. I also know if you do an online search you’ll find a pdf download on how the EFI works.

Known and been used by a few ppl on here (mainly ones who no longer post) for working on their XRs and responsible for most of the most powerful XRs in the UK.

If you go on the Facebook site, look for Art, (Arthur Hernon), he’s had 11 XRs and currently has one of the top 3 horsepower ones in the UK, he will vouch for Boz.
After me you're first :twisted:
molymax
Posts: 3
Joined: Sat Jan 23, 2021 1:08 pm

Re: Electrical Meltdown

Postby molymax » Tue Feb 23, 2021 11:06 am

Thanks Rob. I'll contact Boz and see what he thinks

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