Not giving yourself enough credit THC!

 

And the more current it draws, to the point that it could (possibly) fry a stock ignition module.

 

I did check the coil. Ohmed out perfectly. That is the frustrating part, nothing tests even remotely bad! I have been wrenching on bikes for 50 years and it's s... like this that drives us all crazy!
I have another Ebay used module on the way. I will replace the key switch first since I have one on the way. I need to check the amperage output of the charging system. Voltage is within specs. I also need to do a voltage drop test on the whole system. Just because something ohms out properly doesn't mean it can carry the required current (iffy connectors/broken wire strands). I even went through and cleaned all of the connectors and tightened them back up.
If all of this fails, I will probably go with the Ultima dual fire so I can keep my coil. I can't rely on the bike anymore. Sucks, because it has been very reliable for 11 years.
Thanks for all of the feedback!

 

Thank you very much for the offer. If I need another one I'll let you know. If the one I test next fails, I think it will be on to an Ultima system.

 

If your coil has been the common denominator through all the different modules, then change it (as mentioned earlier). It may test out fine, but change it anyways. YD

 

I recently had the same results on my '94 FXSTC.

Coil ohmed out fine but no spark.

Here is the thread if you're interested
https://www.hdforums.com/forum/evo-c...r-8-miles.html

 

Update. I replaced the ignition switch and coil and installed another Ebay used module. I don't want to jinx myself, but so far so good. Several rides in really hot weather and no issues! I sure hope the coil was it and I can rely on my bike again.
We had a problem with V-6 outboards in the Navy that would have electrical problems after the engine got hot. Of course when they cooled down back at the shop we couldn't find the problem. I started putting the stators in an oven and then testing them. The heat would short the windings. I'll have to test my old coil the same way one day and see if it shorts.
Thanks for all of the feedback guys!

 

Put your Volt Ohm meter on 120 AC. Hook it to your battery and run it up to apx 2000 RPM. Do you see any AC voltage leaking across the diodes in the voltage regulator?

Have seen it numerous times on older cars of the 70 and 80s. Takes out the electronic ignition systems dwell to fire the coil. Before the OB2 system. The ECM bikes protect itself against reversing the DC. Probably AC. Your's probably does not even do DC let alone AC protection.

 

??????????????????

 

Make sense now above? When the diodes in the regulator get old from heat, they usually short out. However, sometimes they short thru and then rather than just allow DC across, they let the AC from the AC alternator on our Harleys come thru.