Old blue stranded me
Outstanding HDF Member
Joined: Oct 2010
Posts: 2,706
Likes: 14
From: Near Frankenmuth, MI
I don't doubt you've checked the battery connections and possibly a portion of the ground connections that are easy to see and find. But if your headlight went out and back on, and the starter button worked, then didn't, then did, you obviously will have a primary power connection that is breaking contact.
Headlight and starters have some common power lines but the intermittent issues point toward something not making full or complete contact.
It may be a failing main breaker but I'm going to guess you still need to unhook each of the main power lines starting at the battery and continue to follow the line from point to point and disassemble the connections, thoroughly clean the surfaces, and reassemble using dielectric grease to aid in contact, and prevent future corrosion issues.
There may even be a major short, like a wire that has rubbed the frame and shorts out your electric system and kills everything simply occasionally.
It's a frustrating issue when it's intermittent. Whenever possible have it running as your manipulating wiring and see if you can duplicate the issue under test situations. Any arc or spark will show you exactly where the trouble is.
Good luck tracking it down.
Headlight and starters have some common power lines but the intermittent issues point toward something not making full or complete contact.
It may be a failing main breaker but I'm going to guess you still need to unhook each of the main power lines starting at the battery and continue to follow the line from point to point and disassemble the connections, thoroughly clean the surfaces, and reassemble using dielectric grease to aid in contact, and prevent future corrosion issues.
There may even be a major short, like a wire that has rubbed the frame and shorts out your electric system and kills everything simply occasionally.
It's a frustrating issue when it's intermittent. Whenever possible have it running as your manipulating wiring and see if you can duplicate the issue under test situations. Any arc or spark will show you exactly where the trouble is.
Good luck tracking it down.
Tourer
Joined: Aug 2009
Posts: 324
Likes: 1
From: Northern CO
I just went through this with my 01. Same symptoms, turned out to be the main breaker. It was shutting off every 2 minutes or so. Cleaned and tightened all ground and power connections, replaced the main breaker. Just got back from Texas on it, ran great.
I would suspect the main breaker first, if not that, the ignition switch, assuming you are losing power to everything like I was.
I would suspect the main breaker first, if not that, the ignition switch, assuming you are losing power to everything like I was.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
I had one of these wretched intermittent problems on another brand bike. When I turned on my indicator at speed, say to overtake another vehicle on a narrow road, the engine would cut! Didn't do it at slower town speeds.
Fortunately I have a friend who is a telephone service engineer and a marvel with electrics, but it still took him a couple of hours to track it down. Turned out to be a slightly loose join between two wires inside an insulating sleeve. Easy fix and no problems after that, but I had very little hair left!
Best of luck tracking yours down and fixing it.
Fortunately I have a friend who is a telephone service engineer and a marvel with electrics, but it still took him a couple of hours to track it down. Turned out to be a slightly loose join between two wires inside an insulating sleeve. Easy fix and no problems after that, but I had very little hair left!
Best of luck tracking yours down and fixing it.
Thread Starter
|
Tourer
Joined: Sep 2010
Posts: 461
Likes: 8
From: western CT
great news turns out 94-98 fl has a recall on the switch, relay, and main breaker 
looks like the dealer will be taking care of this 1 for free. you prob qualified for this too traildog? just go to mocos website and register your bike it will show recalls open and closed. if you still have the oem vacuum controlled tank valve that was recalled as well
looks like the dealer will be taking care of this 1 for free. you prob qualified for this too traildog? just go to mocos website and register your bike it will show recalls open and closed. if you still have the oem vacuum controlled tank valve that was recalled as well
Last edited by nyokie; Jun 16, 2012 at 01:02 PM.
Stellar HDF Member
Joined: Apr 2009
Posts: 3,039
Likes: 11
From: Northern Ontario
I'm amazed that HD honors recalls for a bike so old. I wander how far back a year they would cover?
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Seasoned HDF Member
Joined: Sep 2010
Posts: 10,238
Likes: 799
From: Indiana
After all this time it would still be free? I'll call the stealership and check.