My 2003 Fatboy has "intermittent" start issues.
During ignition "on / run-stop on" - if the '"check engine" light does not momentarily illuminate (BIT) along with the "Security" light - the start switch becomes inop - NO start - no starter engagement. This condition is intermittent. Apparently some condition the "check engine" feature is seeing is intermittently disabling the start.
Notes:
Normal start includes both the "check engine and security lights coming on and back off after 5 seconds (BIT). Then normal start occurs.
Dash / headlight/ passing lamps/tail and turn signals function normally - no flashing.
After normal start - no check engine or security light on....no flashing turn signals - all normal.
I can not for now, retrieve DTC from my odometer, as the indicator display has failed ( 1 or more years ago) as several digits are blurred, faintly illuminated. I am sourcing a replacement Speedometer.
Has new battery & cam position sensor. Battery cables are clean with double ground cables. New hand control switches installed 6 months ago with handle bar swap (apes) - no damaged wires. ( I recently rechecked the switch wires and replaced again the Rh switches). Main wiring harness from steering head (both left and right) replaced 6 months ago (apes)
All electrical connections cleaned, including switches, connections, relays, fuses. Starter relay swapped with a new relay.
I can start the bike multiple times and ride normally, maybe start again and again...then for reasons unknown...no start. It will start again after some inconsistent amount of time..could be 30 minutes or 24 hours...but...if the "check engine light does not flash with ignition on...it will not start. Engine runs fine after start and never fails.
I installed a remote starter switch on the starter years ago when this issue first started, but now when this condition presents itself - the remote will engage the starter but no spark.
Dealers in the Philippines will not work on old bikes or bikes not sold in Philippines..mine was imported from USA many years ago and usually gives trouble free service. I research and perform my own service, have a complete and proper tool set.
Bike was originally an EFI model, but converted to carb 14 years ago by a by a competent HD Tech, with no issues until this current condition.

Question is: What associated with the Check Engine light - is disabling the start ?
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Apologies for the lengthy post, just wanted to present a full description.

All comments greatly appreciated.

 

i know the ignition switch does get corroded terminals under the console. That would be a good place to start.

 

Does it have the Security module TSSM, or just turn signals TSM....?

If you have the security module, just a guess, but maybe it is developing a glitch and may need replacement... I don't know how to check that, especially since the issue is intermittent..


My normal advice would be that this problem could be a connector issue... I would normally say recheck any recent work involving connectors, by checking for bent/loose connector pins...

You've done a lot of work on it in the last 6 months, many things to do with switches and/or wire harness replacement... So my usual advice would involve a bunch of work, but it may still be the way to go...

Sorry I couldn't give better, more specific suggestions... Hopefully someone who experienced similar symptoms will post up with their fix...

Too bad you switched from a Delphi EFI back to Carb.... I have a 2003 with Delphi EFI and can read/clear codes with the HD code reader or most aftermarket tuners (including my PowerVision Tuner).... With a carb ICM, it is not as convenient as with the ECM to read codes...

Good luck and keep us posted on your diagnosis & repair

 

Thanks for the thoughts. Yeah, the carb conversion was performed by the previous owner. I will revisit the ignition switch, although recently serviced

 

UPDATE:
I recently installed a "new take off" KPH OEM Harley Speedometer. Speedo initializes properly and appears to function normally - but cannot seem to pull DTC. The method I am familiar with:
1) Reset button in - ignition switch on --- no codes...
2) ignition switch on rapidly 3 times....no codes...
Bike still has intermittent start issue, but now is becoming a 90% fault. Again, if "Engine Check" light does NOT come on switching ignition switch on - no start
If the "Engine Check" light does come on....then out after 5 sec ...normal start.

I am pulling the TSSM for another inspection and sourcing a replacement. It will have to be a used module as this part is on 30 week back order from WWW.harleydavidson.com.

 

So now, having replaced the Speedo, ECM and TSSM - I get the "Engine" light when switching ignition switch on (start /run - start) but NO security light. This was the original issue intermitently, but is now consistent. I have performed the TSSM/ECM marrying procedure. No start....before replacing the 3 items, the issue had already become consistant.

 

The Engine light comes on and goes out upon ignition switch on....does not come back on. The Security key light...does not intialize. No start

 

Not sure but believe you wanted the TSM not the TSSM as that has the security built in, that is what’s keeping you from spark.

 

delete

 

.Now...(next day) no "engine light - no security light" upon ignition switched on. (Start/stop switch in run)