Bike stalls @45-55

[AZ_BigDog]

hoping you guys can provide some assistance in pinpointing a problem i'm having where my bike keeps stalling while riding. Here are the specifics:

-2007 Mastiff
-11,300 miles - all services performed on a regular basis
-Bike will lose power and totally cut off while traveling at about 45-55 miles an hour, doesn't seem to stall out at speeds lower than 45
-speedo needle will drop below zero, return to 60 and then gradually drop as the bike rolls to a stop
-no problems starting, even after it stalls it'll start right back up
- doesn't lose total power - headlight, tail lights, turn signals, etc remain on
- took it to the dealer, spent 2 weeks in the shop, just picked it up today
- dealer stated it was a problem with the right wiring harness and replaced it
- work order states "ASSY, PCB, CONTROL, HANDELBAR, RH" and "R&R RT. SIDE H/B SWITCH"
- got it home, took it out for a test run....same thing happening.
-gonna take it back on monday :angry:

i truly appreciate ANY suggestions you guys may have.

 

[BBChopper]

Check your gas cap vent!!!!:2thumbs:
Next time it happens loosen the cap up.......

 

[AZ_BigDog]

as some of you may remember...i'm quite mechanically challenged is the gas cap vent the little white thing on the bottom of the gas cap?

if it is...i took that off when i first heard about it on this forum about 2 years ago...

 

[superduty]

my 05 chopper does the same thing. funny thing it all started when bdm did a recall on the switches in the handlebars. 1st thought it may be vent problem, but noticed a drip of gas running down my tank just before it happened once.

 

[Baby Ray]

Well don't know much but does it a have a fuel filter, maybe has a clog

 

[BigDogBro1]

Have the ignition switch inspected for an intermittent connection. Sounds like the ignition is interrupting and the speedo is resetting to 60 as if key switch power-on reset.

Don't hang anything with any weight on your keychain.

You said-
-speedo needle will drop below zero, return to 60 and then gradually drop as the bike rolls to a stop
-no problems starting, even after it stalls it'll start right back up
-doesn't lose total power - headlight, tail lights, turn signals, etc remain on

This is possibly an ignition switch problem.

 

[Can-Dog1]

Sounds like the vibration at higher speeds is causing some type of short in your ignition.

 

[pig pen]

Last igition switch failure I saw the head lite would also go out.

 

[Staffy]

Have the ignition switch inspected for an intermittent connection. Sounds like the ignition is interrupting and the speedo is resetting to 60 as if key switch power-on reset.

Don't hang anything with any weight on your keychain.

You said-
-speedo needle will drop below zero, return to 60 and then gradually drop as the bike rolls to a stop
-no problems starting, even after it stalls it'll start right back up
-doesn't lose total power - headlight, tail lights, turn signals, etc remain on

This is possibly an ignition switch problem.

I'm with BigDogBro1 on this - and to pig pen's mention about the headlight - good point but it could be just a loose connection that "resets" - what concerns me here is, if it is an ignition reset/loose connection, should the bike come to a complete stop or fire right back? (if you pull in the clutch when it stops firing it makes sense if not I'm at a loss)
good luck...let us know

 

[Roaddawg]

I had the same problem on my '05 Chopper early in the season. The dealer quickly identified it as a bad tachometer board. Just a small bit of corrosion on one point where a wire was soldered to the board. They replaced it and it has gone several thousand miles now, trouble free.