My 1997 Ultra suddenly has a stuck radio at full volume. The volume switch does not control the volume. I have disconnected the wiring harness and the radio stays a full volume. I keep the dash switch off and can listen to the passenger speakers and adjust the volume back there.

Any simple fix for the front speaker volume?

 

Did you wash the bike or get caught in strong rain? Could just be wet and needs to dry out.

 

I washed the bike and it sat for a couple of weeks before I noticed it. It was real hot here in Texas and I did not ride for those two weeks. When I went to get it out of the garage, the volume blasted me off the bike. I have the switch completely disected out of the handlebar switch housing and have sprayed cleaner and other switch wash with no permenate results. It did work once for two minutes after spraying an electric motor cleaner. Came back on full volume and nothing since works. I am currently searching for a used wiring harness to possibly replace this one.

 

disconnect the battery for a minute or so.. that will reset the radio..

 

Good idea, no result, thanks.

 

Well, the problem is located in the DIN cable between the radio and the junction with the CB. Short somewhere.

 

I have this same problem. Where did you find the short. I am going to disconnect the battery and try to reset it but dont think it will work for me either. I rode in the rain washed it and let it sit for a couple of days. Had to rewire the alarm and when i turned the switch on the voulume was and is full blast. Everything else is working fine just the volume control is wide open.

Robby
93 Heritage
97 Ultra Classic

 

Had same problem with my 97. Had to be carefull when I washed it. Would still happen when I got rained on. Had to let it dry out before volume worked. I tried a new cover on top of the radio, but didn't help. Got a biketronic control and changed it out to a Sony. Still have the radio and an exrta Biketronic control. New setup worked great and gave me a cd/mp3 player.

 

The problem is not the radio. Order this part from your local Harley-Davidson dealer, H-D P/N 76292-95. This is the DIN cable that connects between the radio in the faring and the console pod on top of the fuel tank. It runs along the back bone of the frame under the fuel tank. When you install it on the bike, pull some of the excess cable from the faring so that it can be looped on the right frame rail and the connector on the end is not strained like the factory did when the bike was built.

If you take the seat off of the bike, the DIN cable will be tied down to the right frame tube near the battery. Notice the tight 180 degree bend in the cable right at the strain relief. This is the source of the problem and has resulted in an internal short that artificially holds the volume at maximum.

This fixed my Ultra. You will need to take off the tank and the front of the faring as well to install the cable properly.

The recommendation came from John Smith, Senior Technical Advisor for Radio Sound. That was 2009 and he may or may not still be there. He was a great help.
John Smith
Senior Technical Advisor
johns@radiosound.com


Good luck!
Mike

 

Thanks Mike....Im still sorting out a mess of wires run to the battery and this will certainly help.