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[vdubjay]

Recently I removed my tank on my 2015 FLTRUSE for cleaning and noticed my front plug wire has rubbed thru the insulation, it's rubbing the underside of the fuel tank.  I contacted dealer they are aware of this problem and said they will replace wires and apply a protective sleeve over the wire "applying a band aid to the problem, not fixing it".  So far I've asked about 10 other Rushmore owners and they were shocked to find the same problem.  I know there was a previous post relating to this problem, I'm trying to make sure everybody know this is an issue and of course HD is not interested in fixing it just covering it up.  Is it just me or does it appear HD learned nothing from the AMF days (Greed prevails, make the cheapest possible product the customer will still buy), I wish I liked Indians. 

[grc]

Recently I removed my tank on my 2015 FLTRUSE for cleaning and noticed my front plug wire has rubbed thru the insulation, it's rubbing the underside of the fuel tank.  I contacted dealer they are aware of this problem and said they will replace wires and apply a protective sleeve over the wire "applying a band aid to the problem, not fixing it".  So far I've asked about 10 other Rushmore owners and they were shocked to find the same problem.  I know there was a previous post relating to this problem, I'm trying to make sure everybody know this is an issue and of course HD is not interested in fixing it just covering it up.  Is it just me or does it appear HD learned nothing from the AMF days (Greed prevails, make the cheapest possible product the customer will still buy), I wish I liked Indians.

A thicker rubber sleeve will take longer to rub through, thus making sure the bike is out of warranty when it fails.  And of course all that rubbing on the paint of the fuel tank will eventually lead to corrosion of the bottom of the tank.  There's another thread that was posted in the past week showing parts of the wiring harness also "chafing" and being worn through where it rubs on the coolant lines to the rear head.  Harley has always made a big deal in their marketing about "tradition", and obviously continuing their history of lousy engineering is part of the tradition.

I'm sure it will all be taken care of when they redesign the frame to make room for all the extra crap they've stuffed in that area.

Jerry

[us1fountain]

I've read this condition before and checked that plug wire on both my bikes. signs of rubbing. I took a piece of vacuum hose and slipped it over the wire. Good for 100  yrs now

[remington007]

The replacement plug wire is fastened to frame different to keep it away from the tank.

[Phantom309]

I also did the vacuum hose/zip-tie trick with mine on day one so never had this problem, both wires still good as new today.

[flhman]

Recently I removed my tank on my 2015 FLTRUSE for cleaning and noticed my front plug wire has rubbed thru the insulation, it's rubbing the underside of the fuel tank.  I contacted dealer they are aware of this problem and said they will replace wires and apply a protective sleeve over the wire "applying a band aid to the problem, not fixing it".  So far I've asked about 10 other Rushmore owners and they were shocked to find the same problem.  I know there was a previous post relating to this problem, I'm trying to make sure everybody know this is an issue and of course HD is not interested in fixing it just covering it up.  Is it just me or does it appear HD learned nothing from the AMF days (Greed prevails, make the cheapest possible product the customer will still buy), I wish I liked Indians.

Glad I read this, mines rubbing also, dealer ordered new plug wire. flhman

[rnich56]

Both my 2014's have the front plug wiring chafing to the tank.  I covered the area with sprial wrap to prevent further chafing.

Rick

[ultrafxr]

Both my 2014's have the front plug wiring chafing to the tank.  I covered the area with sprial wrap to prevent further chafing.

Rick

Same on my 2017 M8 CVO Limited.  Showing slight chafing on the front plug wire with 9,000 miles.  Used about 4" of split wire loom to cover it.  Hopefully that'll take care of any problems.   

[MC16LTD]

If you have a Rushmore 14-16 touring bike (may effect other models as well) check your front spark plug wire.  Was discussing with my friend and a user group on Facebook, seems the Rushmores' have an issue with the front plug wire rubbing the sheath off against the gas tank.  My bike has just over 8000 miles and the sheath is probably worn 1/3 of the way through.  If it wears through you may be sparking of the fuel tank or missing (more so if raining).  Off to the dealer next weekend for some warranty coverage.

[RonandJanet]

I will look at mine today.

[Saxton]

Every 2015 cvo 110 has this issue. In warranty repair approved but the MO is not notifying owners.

Sent from my Nexus 7 using Tapatalk

[ultrarider123]

Glad I checked this post.  I rode to work today so walked out to the bike and yep, rubbing on mine, too.  A bit of electrical tape, a tie wrap to keep it off the tank and a call to the dealer to investigate for corrective action.

Thanks for the heads up.

[flhman]

Not just the CVO's either, they all do that, isn't that the standard response ? Friends 15 Road Glide is doing it, another's 17 is also. flhman

[HDMIKETN64]

My 2015 RGS had similar issues. They route the wires through the gas tank/frame tunnel, which just asks for troubles. I put the 10mm red SE plug wires on it at 15k miles and made sure they were not in any position to rub. With the new M8 114, I have no idea where they run the wires, but I'm guessing it's through the same tunnel.

[us1fountain]

I just  take a section of vacuum/fuel hose, slit it and slip over the wire. Done this on my '15SGS and my '17 CVO. Both bikes had same rubbing

[muddypaws]

That would be a bummer if it went through..

[Road Dad]

Just checked mine (14 CVO) same rubbing. Another wonder of American engineering. You think after a hundred year or so of making bikes they would be able to design / manufacture a pretty good product but unfortunately not so.

[HOGMIKE]

Same issue with mine
2016 cvo limited
I'm a long way from home but wrapped a little duct tape to get me to a dealer to replace it.
Thanks for the heads up
👍

[Twolanerider]

Is there room on these to just install a piece of split vacuum line or some other maybe even skinnier plastic tube as an insulator?  Perhaps not (this is Harley after all)?  If there is I'd just do that and never worry with it again.  Granted, it cuts HD (yet another) break.  But it would save me the hassle of dealing with them.  I'd save that frustration for whatever comes up next (and there always is something next with Mother Harley) that wasn't as simple.

[SteveVO]

Thanks for posting this, I would not have know to check it if you hadn't posted. I checked mine the other day and it was worn half way thru also.  15 CVO SG, I wrapped some elec tape around the rubbed area till I take it in for it's 10K service.  So what is Harley's permanent fix for this?  New plug wire and another zip tie to help hold it away??

[Road Dad]

I put a piece of reenforced rubber hose around it. That will be the permanent fix.

[Trigger-Man]

If you have a Rushmore 14-16 touring bike (may effect other models as well) check your front spark plug wire.  Was discussing with my friend and a user group on Facebook, seems the Rushmores' have an issue with the front plug wire rubbing the sheath off against the gas tank.  My bike has just over 8000 miles and the sheath is probably worn 1/3 of the way through.  If it wears through you may be sparking of the fuel tank or missing (more so if raining).  Off to the dealer next weekend for some warranty coverage.

Thanks for the heads-up. Just checked mine and same-ole Dealer recently had the gas tank off to route Stage 2 audio system ........you'd have thought they'd notice ! As this issue appears to be wide-spread ......they should have at least checked!!!!!!!!!

[RonandJanet]

Wow!  I have got to find time to check mine!

[KGB]

Just checked mine, 11000 miles and there are no marks on them, going into dealer tomorrow for new tank (paint peeling where cap seal is) and stain marks on inside of speedometer.

[OhioDave]

 Mine is nearly worn through....thanks for the heads up 

[bigC]

Just checked and my 15 has the same issue.

[4fun]

Thanks for the heads-up. Just checked mine and same-ole Dealer recently had the gas tank off to route Stage 2 audio system ........you'd have thought they'd notice ! As this issue appears to be wide-spread ......they should have at least checked!!!!!!!!!

Looks just like mine, just checked it. Put a piece of rubber hose over it for now. I need to check the bottom of the tank, it feels like it may have rubbed the paint away.

Sent from my SM-G930V using Tapatalk

[grc]

Just sliding a piece of tubing over the plug wire may slow or prevent the damage to the plug wire, but don't forget all that rubbing on the tank will probably rub through the paint at some point, leading to some rust issues.  Don't give Harley another free pass on this, make them fix it so nothing rubs, period.

Jerry

[IRNEngineer]

Another great reason to be a member of cvoharley.com forum! I just rode home from my 10,000 service and checked my plug wire. Almost worn through! Why wouldn't the technician check this if it's so common? Sure glad I've got you all to keep me rollin!

[grc]

Another great reason to be a member of cvoharley.com forum! I just rode home from my 10,000 service and checked my plug wire. Almost worn through! Why wouldn't the technician check this if it's so common? Sure glad I've got you all to keep me rollin!

Makes you wonder what else they don't check during that overpriced "service", doesn't it?  Why don't you swing by and ask the service manager that question?

Jerry

[ultrafxr]

Makes you wonder what else they don't check during that overpriced "service", doesn't it?  Why don't you swing by and ask the service manager that question?

Jerry

Ten to one he will tell you he's never heard of this. 


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[ultrarider123]

Ten to one he will tell you he's never heard of this. 


Sent from my iPhone using Tapatalk

Exactly the response I've got from all three of the service departments at our local dealers.

[moscooter]

 
Checked my '14 SG Special,  yup some wear thru starting to happen.  As a streetrodder,  I had a box of old wire loom plastic corrigated stuff and put a short section over that plug wire.  Problem solved.  You can get that plastic wire loom stuff (split lengthwise).......so all ya have to do is slide a section over the wire and you're done.  Can get it in various sizes from your auto store or go to any auto junk yard and peel some out from under the nearest hood.

[Trigger-Man]

Every 2015 cvo 110 has this issue. In warranty repair approved but the MO is not notifying owners.

Sent from my Nexus 7 using Tapatalk

As my factory warranty had expired back in March, I'd purchased the Cornerstone ESP from Jim Palmer. My dealer politely informed me that Cornerstone rejected my claim as "Plug wires are a maintenance item" which are excluded per the contract. As my dealer was out of stock with replacement wire .........I wound up paying for a set of RED SE wires ..........with labor $108

[4fun]

Guess I am in the same boat as you.

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[RonandJanet]

Finally checked mine and there was some rubbing. I put some plastic split wire loom on it (about 5 inches) and it covers the wire up past the rub point. Glas this was called out!

[fastfreddy]

Dang ?? Seen this and remembers I had dealer order me one about a month ago ... sux getting old

[Joel]

You can bend the connector that pushes onto tbe spark plug to give it 1/4 inch clearance. I did this with mine as well as one for a guy I met on my last road trip. His also had wear, and this helps keep the wire from rubbing the tank.
Just do it when engine is cold. Doesn't burn you that way.

[ultrarider123]

You can bend the connector that pushes onto tbe spark plug to give it 1/4 inch clearance. I did this with mine as well as one for a guy I met on my last road trip. His also had wear, and this helps keep the wire from rubbing the tank.
Just do it when engine is cold. Doesn't burn you that way.

Very good advice.  However, I believe the burning occurred when I signed the bill of sale..... 

[fastfreddy]

Voter replaced ... Thnx for the reminder. 👍🏽

[SHRADER]

Checked my 14 Road King Saturday and front plug wire had been rubbing enough to wear a divot in it. I cut a small section of fuel hose I had, split it and then trimmed it to tightly fit the wire. I put this patch over the plug wire and zip tied it tightly in place. Will get a new wire when I return from MV.

Seriously this is BS on HDs part. We shouldn't have to fix their mistakes all the time.

All folks with a 14 or newer should check your front plug wire just under the front of the tank.
Bet yours is rubbing too..

[ultrarider123]

Yep.

There is actually another recent thread on this topic:
https://www.cvoharley.com/smf/index.php?topic=112435.msg1436601#msg1436601

Maybe the moderators can merge the two?

[grc]

Checked my 14 Road King Saturday and front plug wire had been rubbing enough to wear a divot in it. I cut a small section of fuel hose I had, split it and then trimmed it to tightly fit the wire. I put this patch over the plug wire and zip tied it tightly in place. Will get a new wire when I return from MV.

Seriously this is BS on HDs part. We shouldn't have to fix their mistakes all the time.

All folks with a 14 or newer should check your front plug wire just under the front of the tank.
Bet yours is rubbing too..

Same problem on the 2017's, so obviously Harley is happy letting customers fix it.

Jerry

[Joel]

You can bend the spark plug end  connector while on the plug inward.
With engine cold, wrap your pointer finger around the boot while it is on the spark plud and with your thumb, feel for the metal connector and push in on it.
This can be bent until you have the clearance you want.
If your wires have been replaced do the same to be sure it clears the fuel tank.