20 Most Recent 2003 Harley Davidson FLHTCUI Electra Glide Ultra Classic - Page 7 Questions & Answers

Top of the trans cover on right side of bike.

I would remove the speed sensor on the transmission and clean it..Just wipe it of. It's probably loaded with metal shavings. If cleaning doesn't work then you'll probably have to replace it. I own a 2000 FLHTC and I have to remove and clean mine at least 2 times a year. As for the engine light being on. The engine light should shut off within 5 to 8 seconds of the bike being started. You need to run the diagnostics through your speedometer. If you don't know how then you need to buy a service manual for the bike so you can do the diags and look up the codes.

... and what happens next? Are you over heating? Out of oil? What have you ckecked or tried to solve the trouble? You cannot just ignore the warning.

It's possible some wires have rubbed through inside the fairing. The usual spot to check in near the two silver inner fairing brackets. While your in there, check the connections at both the radio and the speedo.

Hi,If the starter winds and there is a clicking sound, but did not crank the engine, it means the solenoid did not engage the starter bendix gear drive to the crankshaft.You have to pull down the starter assembly and check the parts inside. By putting a direct power to the starter you will see what's wrong w/ it.If you have no knowledge on such repair, a technician should do the job!Tell me if that solved your problem so that I could guide you for repairs.Hope that helps!.

Thats is strange ..springs..!! I do not know ..sorry ,, If you wish you can join & post that ? on our forum harleytalking.com . good tecks there ...good luck.. ultrat..

I believe its under the rt side cover located just below the fuse box ,,Thats where it is on my 09 flh,, sorry pin # i do not know ......

You need to check the charging system. To do this you need to fully charge the battery and you'll need a good Digital Volt Ohm Meter. Using the meter's function selector switch, set it to DC VOLTS with a range of 20 volts or greater. Connect the red meter lead to the positive battery post and the black meter lead to the negative battery post. Start the engine and bring it to a high idle. After about a minute or so, your meter should read between 14.5 and 15.0 volts. Any lower than 14 volts, your battery will not be charged.

If you don't have the minimum voltage at the battery in the previous test, you need to check the alternator to see if it's generating sufficient voltage. You'll have to follow the wires from your voltage regulator going to the lower left front of your engine until you come to a plug. Unplug the plug and look into the engine side of it. You'll see two metal contacts in the rubber plug. This is where you are going to test the voltage from your alternator. Since you'll be testing AC voltage, it makes no difference which meter lead goes into which contact, just one lead into each contact. Set your meter's function selector switch to AC VOLTS with a 50 volt or greater range. Start the engine and bring it to a high idle. Insert one meter lead into each of the metal contacts. Do not let the leads touch each other or the engine case or ground. Your meter should read at least 25 volts.

If you do not have the 25 volts from the alternator, your stator is bad and must be replaced. If you have 25 volts or more but not the 14 volt minimum at the battery, your voltage regulator is probably bad. Make sure you voltage regulator is properly grounded. Check the condition of the wire coming from the regulator going to the battery. This wire is usually larger in diameter than the other two going to the alternator.

Your bike came from the factory with H-D 20W50 Syn3 engine oil in the engine, primary case, and the transmission. There are other oils available such as Amsoil, Mobil, Royal Purple and many more. Check their websites for compatibilty.

Steve

The oil tank is on the bottom of the transmission. The engine oil drain plug is on the left front corner of the oil tank. Drain the oil, change the oil filter, and refill with three quarts of any approved 20W50 weight engine oil. Check the oil level using the dip stick. The dip stick is located on the right side of the transmission. The oil cap is a large cap (2" or 50mm in diameter) with knurled edges on it. The dipstich has two marks on it. The top mark is 'FULL HOT" and the lower mark is "FULL COLD". Keep the oil level between these two marks. Check the oil level with the bike on the side stand.

Good Luck
Steve

I also have a 2003 Ultra that would shut down for no reason while I was driving, started happening 3 months after I had the bike, very dangeous, happened in a curve once, took it to the dealer and they were having problems a module for the ignition I thought. They replaced it twice, then told me that because I had a trailer wiring harness hooked up that was causing interferance, they took that off and havent had the problem since. Didnt use the trailer hitch much anyways, but dont know at this point if it was the module or the harness. Hope this helps.

When a problem is encountered after something has been done go to the last thing you did ( put grips on) and check what was done. Look for pinched wires binding cables whith housing open and closed. A card board spacer has to be inserted in crack between front brake lever and housing to retain internal piston in handle bar assy. or damage to front master cylinder piston can result (brake won,t disengage as plastic piston gets stuck.

Sounds like the front brake assy. on the handle bar was removed without the card board insert installed between the front break lever and the little piston which can damage it and cause the front brake switch not to work right as the piston in the handle assy. won,t slide back and forth when the lever is moved in and out

A few questions first, Is it hard starting,lag on acceleration,engine hotter than normal?

900-1000 RPM.

Your Voltage should never get that high. Anything over 15volts is bad news. Try Testing your Regulator. First do a Bleed Test.
REGULATOR BLEED TEST
Be sure regulator is connected to battery. Unplug the stator connector.
Use a trouble light and clip it to a good ground and the other to the regulator pins, one at a
time. If light comes on regulator is bad.

If you mean that when the fuel goes down in level to 5/8th of a tank then check the fuel filter above the fuel tap.

Usually caused by the clutch being out of adjustment. Start by loosening the clutch cable at the midway adjuster. remove the derby cover, (over clutch), which will expose the clutch adjusting screw and nut. Loosen the nut, turn the screw in until you feel resistance, no slack in screw, then back the screw out 1/2 to 3/4 turn, then tighten the lock nut. Pull the clutch lever a few times to seat the clutch release mechanism. Adjust the cable at the midway adjuster, holding the cable tight away from the lever. Adjust until there is 1/16" to 1/8" free play between clutch lever mount and the end of the cable housing. Lock the adjuster with the jamb nut and slide the rubber boot back over the midway adjuster.

Look under the seat on either side. There's usually a single bolt on each side screwed upwards into the seat pan.

Under the seat in front of the battery