After waiting a week for the dang special order, got the new switch - looks different even than the one they replaced in the recall. Test drove 15-20 miles, perfect!

Until this morning.

Shortly after starting out to work, the headset cut out. Toggled the speaker switch, headset back in. Happened a couple more times. Related? Hmmm ...

About 20 miles or so into the ride, and - of course - just as a pop-up rain shower started (NOT on radar!), same thing: out, then back in. Three more times in the next few miles, then it cut out completely. IN the rain, raingear IN THE TRUNK. Fired back up fine about 30 seconds later. Managed to get to work. No issues in the buzz-out.

Maybe contact cleaner on ALL connectors under the fairing, another buzz-out, and a few rounds of Jose Cuervo ... not necessarily in that order.

 

On the way home from work ... stranded.

Relay clicking under the seat. Holy hint, Batman.

Damn.

 

More research led me to the main breaker - apparently the original had some problems just like the the ignition switch (found a lawsuit about a death caused by a failed main breaker) - so I picked up new one for $8.00.

Got home to try it, same problem - click, click, click. So I started to removed every connection, one by one, until I found the problem. It was in the charging circuit from the regulator.

As it turns out, one of the lines coming from the voltage regulator into the main circuit breaker had found its way against the exhaust pipe, and melted. It was intermittent until completely melted through, and once it was complete and the main breaker just kept resetting.

Since I have a Cycle Electric regulator I believe I can order a new cable. But in the meantime I put in a big honking butt splice (wire is too big for my soldering iron to handle).

Runs fine, but now I have no turn signals, brake light or horn. I know there's a connection missing somewhere…damn...

 

I have the exact same problem as you on my '93 FatBoy. The bike intermittently cuts out. I first tried cleaning the ignition switch and that didn't help. I replaced the ignition switch and that didn't help (the old switch was worn, 98K miles on the bike). I haven't found the time to trace out where the problem might be so I've stopped riding the bike since I didn't want to get stranded. I think you've motivated me to dig in, find and fix this problem.

 

I keep working on it because it's 40mpg with the bike, or 15mpg with the Powerstroke. Rather spend the $$$ on booze, not fuel. Plus it's buggin' me that I can't ride!!!