I have a 2004 fuel injected Softail Standard FXSTI. At 50,250 miles, due to a failed inner rear camshaft bearing, a failed chain tensioner, or a combination of the 2, I had to do a complete rebuild of my engine.

I went back together with all S&S 509 gear driven cams, adjustable push rods, oil pump, and cam plate. I also used Cometic gaskets.

After initial startup and a few short trips from the house, I had a few problems to work out.

After resolving those problems, and making a 35 mile run to Corpus Christi with several stops, and returning home, I started having electrical/start problems.

1. Turn ignition on and the breaker would trip

2. Turn ignition on hit the start button and breaker would trip

3. Turn ignition on and bike would try and start by itself. I never let it turn over enough to start.

4. I engaged the solenoid start button, and the bike started without the ignition being turned on. Turning the ignition on and then off did kill the engine.

5. Going down the road, the bike would die. After several minutes, it would start up again.

After talking to several people, the primary thoughts were a grounded wire, ignition switch, start/kill switch, or possibly electronics.

After checking out what I could, I told my local wrench that I felt that my start/kill was sticking or the wiring was grounded, and I was going to replace it. He told me that he felt I was pissing in the wind, and should bring it in and let him chase it down. Not being electrically inclined, I took the bike to him.

After an hour and a half of labor, he replaced the 5 prong starter relay, which I had already replaced, with a 4 prong starter relay.

350+ miles later, no problems. Has anyone else had these problems, or is anyone else aware of this fix?

 

The start relay was stuck, the guy fixed it, what more do you want?

The 4 pin relay does exactly the same thing as the 5 pin relay on your bike, because your system only uses 4 of the 5 pins.

 

Dan89FLSTC, thanks for your response, and you are right, my bike is fixed, but there is something more that I want.

I want to understand why the stock 5 prong relay and the new 5 prong relay that I replaced it with both passed the diagnostic test from the service manual, but didn't fix my problem. I want to understand why a 4 prong relay fixed a problem that I didn't have for over 50,000 miles with a stock 5 prong relay.

JP Cycle showed that both the 5 prong and 4 prong relays were compatible with my bike.

The bike is fixed, and for that I am grateful and thankful. However, I am blind to understanding exactly how it was fixed or exactly what fixed it.

That fifth prong on the relay and the fifth slot in the relay panel are there for a reason, but until I understand the how and why, then there will always be a question in the back of my mind about the "fix".

All comments are appreciated.

2002 Sportster Custom 1426cc,101.5 hp, 100.2 lb tq, 107,000+ mi, 2004 Softail Standard 1450cc, 55,500+ mi, 2018 Softail Low Rider Milwaukee 8 107 cu in, 2,870 mi

 

"That fifth prong on the relay and the fifth slot in the relay panel are there for a reason, but until I understand the how and why"


I believe that is the answer to your question...

Often a manufacturer will make a part that is compatible across several model lines.... cheaper to manufacture that way.


"I want to understand why the stock 5 prong relay and the new 5 prong relay that I replaced it with both passed the diagnostic test from the service manual, but didn't fix my problem."

You will probably never know the answer to that question...

Since the facts are that; the stock 5-pin didn't work, the new 5 pin didn't work, but the new 4 pin did work... I would suggest that the original went bad, you got unlucky with a bad replacement part (it happens), and you either didn't perform the diagnostic check correctly, or that check is not designed to show the problem your relay had....

There are a multitude of possible, but less likely scenarios....but now that it's fixed, you'll never be able to figure out which one could be the culprit. It sure sounds like whatever it was, it was centered on the relay.... the newest relay fixed it... I'd be good with that.... If it should raise it's ugly head again in the near future, at that time you could dive deeper into the possible problem(s)/cause(s)..

For now, I would just accept the repair as fixed...

 

I Can`t explain how the mechanic fixed the issue, your description sounded like a wire was shorting to ground, possibly it was a simple issue the mechanic found and fixed and didn`t even mention it...

As far as the difference between 4 pin and 5 pin relays....

The extra terminal on the 5 (87A) relay is not used on your particular application.

Some older bikes did use the extra terminal, for instance, some bikes used this extra terminal to supply power to the headlight, since it is powered when ever the ignition switch is on, but it does not have power when the start switch is pressed, this causes the headlight to shut off when the starter is cranking.

This type setup is not necessary on a modern Harley starter setup, and the factory got away from it pretty quick.

 

Appreciate the responses. Most of the people I've talked to felt that it was a ground problem. However, I asked the person who worked on it if he had found a ground, and he said he didn't.

I have several hundred miles on the bike, and the consensus seems to be just ride it. Can't say that I disagree.

2 years ago at my 50 year high school reunion, we decided that we should have a 70 year birthday party. So 700 miles from Aransas Pass, Texas to Arkansas City, Kansas in September is on the docket.

Once again appreciate the responses.

 

Put the old 5 pin relay back in see if it does it, if it don't you know they done something else for your piece of mind.

 

Have thought about that a couple of times, but keep going back to if it isn't broke, then don't fix it, but the reality is that eventually I will do that.