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I have an 09 Fat Bob and have had three relay failures since I bought it in September 08, two system relays and one starter relay have failed. The first time I had a system relay go I wound up pushing the bike home the starter relay went next but I was still in the garage by the time the second system relay went I was already riding with a pocket full of spares. It's out of warranty now so I've gottaa fix it myself now, I'm just not sure if this is an inherent problem with these bikes or I have something wrong that is damaging the relays. Has anyone had the same problem? If so have you found the solution? Help please! I want to leave on the bike without a pocket full of relays for once!!!
Thanks for the link, sounds like I'm not the only one with relay issues. Too bad there are no fixes for it. Not too much humidity here and I don't ride in the rain if I can help it but the fuse box on my bike gets really wet every time it's washed. I blow it out and keep all the connectors covered in dielectric grease and I was pretty sure corrosion was the issue until I cut one of them open and found that the contacts were burnt. I think it might just come down to $hitty components.
Poor connections and corrosion can cause heat to increase that will burn contacts.
Think it is a bit of both, weak components (under rated) and the increased likely-hood of corrosion due to location of components.
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