my bike would not start. 89 softail fxstc stock. I hear the click of the relay and nothing else. when I release the "start" button it sounds like the plunger coming back. it's only happen when I stop to get gas, when I have to turn off bike, but try to start within 5 minutes later. I Bypass the relay direct from battery to starter and it fires right up. I get home; and everything seems fine. Can't duplicate the issue.

 

 

Clean the connection (tan wire) at the main breaker (this is the power source for the start relay).
Clean all connections at start relay (consider replacing the relay).
Clean the connection at the solenoid (green wire).

 

seems to only happen if it's hot. I have not check timing or anything. Also found there was a recall on the starter relay getting to hot and possibly causing fire so it looks like Harley left the old one behind the oil filter and used an extension harness to move it next to the coil under the seat. I've got no problem just swapping the relay. just looking for a little confidence that I won't get stranded next time I get gas.

 

This issue has nothing to do with timing.
Forget that it only happens when it is hot, the fact that it happens at all is the issue to focus on.
You say when the starter solenoid is powered directly from the battery that the problem does not occur, this tells us that it is most likely a starter relay circuit issue.
The relay was not originally mounted near the oil filter, that would have required about 6 feet of battery cable.
I think the relay was originally mounted on the rear fender extension near the main breaker, but they got too much water in them and would fail, causing the engine to crank by itself...(it happened to me on my `89 Softail), the recall moved the relay to a spot under the seat, and also replaced the battery cable (the relay that was put on my bike for the recall in `89 is still working fine....).

 

I stand corrected. I did mean oil tank, I just wasn't sure what to call the rear fender extension. so i have to a relay I know isn't working right. One I am unsure of; but works right now, and will be getting one new shorty. Thanks again for all your help!!!