Need some thoughts on an ignition problem
Please look up the ignition switch recall and the leaky vacuum operated fuel valve. I had the ignition switch issue do similar things to my bike. It's a safety recall. They never go away. The recall can be found using the VIN. I found it when I joined HOG. I think #96v-204 is the fuel valve and 96v-158 is the ignition switch. The fuel valve has been fixed on my bike for a long time, but the switch causes low voltage or no voltage problems. This recall effected bikes built from 1993- 1998. Mine is a 1994 FLHTCU built in 1993. The recall fix is free, and they replace the switch and add a relay. My dealer had to order the kit and just did the repair last week.
Good luck, Sam
Good luck, Sam
NHTSA Identification Number: 98V-158
Date of Company Notification: 7-9-98
Make: Harley Davidson
Models:FLHS, FLHT, FLHTC, FLHTCI, FLHTCU, FLHTCUI, FLHTP,
FLTC, FLTCUI, FLTR, FLTRI, FLTCU
Model Years: 1994-98
Number of Vehicles: 55,013
Mfg. Campaign No. (N/A) Ignition switch. DOM: 4/93 6/98. Loss of electrical power through ignition switch can occur due to excessive current and other factors. This can cause engine to fail to start, operate erratically, or stall. (Correct by replacing ignition switch/circuit breaker and installing relay kit.)
Road Warrior
Joined: Apr 2016
Posts: 1,528
Likes: 933
From: Long Island
Thinking outside the box here, if you’ve got the FSM, go to the wiring diagram and jumper the switches and put a toggle switch on the hot wire feeding it.Maybe hide the switch under the seat and you can still use steering lock on the switch.At least you can nail down if the switch is in fact your problem.
Intermediate
Joined: Jul 2019
Posts: 42
Likes: 32
From: NOVA
Before I found out about the recall, I was going to install a relay to handle the Ignition switch loads. I did look on ebay and found the kit from HD to do the job. Definitely bypass the switch and test.
Last edited by Sam Childress; Nov 17, 2022 at 06:35 PM.
Sorry I was out of town for last week, I do have the new switch. I have not installed it yet. When I had it apart before I noticed that the switch is connected to the circuit breakers under the fairing. Unlike previous times, where I would still have marker lights, currently I have no power except dash/radio/turn signals. Is it possible that besides a switch issue it could be something with one of the circuit breakers?
As far as testing the switch and jumping it out, that's probably going to be my net test. I'm in the process of rebuilding the motor in my dyna as well so Im trying to get one up and running quickly so I have something to ride.
Another thought/question. I know that unfortunately the previous owner added new bars to the bike and instead of extending the wires at the end or being smart and soldering them, they used butt connectors in the middle of the bars. The wires are so tight in there that they will probably never come out without cutting the bars. That being said is there anything within the wiring of the bars that could cause my issue? Just wanna make sure i'm looking in the right spot? I had an issue recently where everytime I hit the brake the radio would power off and then back on. Which baffled me, but corrected it self once I took the bars off and moved everything around the last time. Now the radio is staying on, go figure that one out.
As far as testing the switch and jumping it out, that's probably going to be my net test. I'm in the process of rebuilding the motor in my dyna as well so Im trying to get one up and running quickly so I have something to ride.
Another thought/question. I know that unfortunately the previous owner added new bars to the bike and instead of extending the wires at the end or being smart and soldering them, they used butt connectors in the middle of the bars. The wires are so tight in there that they will probably never come out without cutting the bars. That being said is there anything within the wiring of the bars that could cause my issue? Just wanna make sure i'm looking in the right spot? I had an issue recently where everytime I hit the brake the radio would power off and then back on. Which baffled me, but corrected it self once I took the bars off and moved everything around the last time. Now the radio is staying on, go figure that one out.
Yeah that's what I was afraid of but the answer I expected. I've been waiting to fix it for years but since it wasnt an issue I left it alone. Just know if it's as bad as described it's gonna be a nightmare.
It took a little bit of time to catch up and get to rip this apart again, but I finally got to it this weekend. The switch was bad, once replaced everything was back to normal. It starts and everything works, but I haven't been able to put any miles on it yet. I'll get it rolling in the next couple days to make sure there are no other hidden issues.
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Tourer
Joined: May 2011
Posts: 469
Likes: 158
From: Alberta
The recall kit mentioned for the switch, actually doesn't include the ignition switch itself. I eventually found out through a Harley Davidson dealer, having him run the vin # that my bike had been fixed back in 1999. Before that had happened, I had bought the kit brand new in an unopened HD package, the actually recall kit. It included relay, circuit breaker and a short piece of jumper cable with the appropriate plug ends. The ignition switch was not included in the kit. So I can only guess that if it was replaced before the lack of relay fried the switch, then they didn't replace the ignition switch.
It's pretty easy to tell if your bike has the recall done, if you have the outer fairing off, you'll see a relay with a yellow strip on it, bolted to the left upper fairing support as you face the bike. If the relay is there, then the recall is done.
It's pretty easy to tell if your bike has the recall done, if you have the outer fairing off, you'll see a relay with a yellow strip on it, bolted to the left upper fairing support as you face the bike. If the relay is there, then the recall is done.
Yeah there was definitely no relay that I could see under the fairing like that. to the best of my knowledge it looks as though the switch had been replaced once before, prior to me owning it. The terminal ends for the switch described in the manual did not match what was installed on the bike, they one on the bike more so matched the new replacement one. Also after looking up the recall it said it was just for 94-98 models and mines a 93? So not sure if I was even part of that recall? But I will research that a little more cause If I can add a relay and do the "fix" myself I will to prevent having to replace this switch again.
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ChrisV
Ignition/Tuner/ECM/Fuel Injection
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