ignition switch caught fire
Thread Starter
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Ultimate HDF Member
Joined: Oct 2007
Posts: 5,257
Likes: 6
From: Leander Texas
your welcome. how did you like those pictures?
I assume you are talking about all the "product shots" in the Ebay store. Yeh, I noticed and very nice. They are local and those pics almost made me pick up in person.
4th Gear
Joined: Jun 2010
Posts: 8
Likes: 0
From: Seaside, OR
I had the same issue
I had the same thing happen to me about a year and a half ago with my 05 Heritage "Fire Fighter Edition" How ironic. I manage to breakdown "on" the door step of a Harley Dealer on a Sunday morning. Bought the Factory switch for...you guessed it....$100.00. Tore into the bike with minimal tools and was back on the road in about 3 hours. The crew at the Harley dealer was very helpful considering the shop was closed. When I enquired about the cause of such an issue, the head tech via a phone call, told me that the terminals start to vibrate loose causing arcing at the terminal. I thought that sounded reasonable but still questioned it. I got home and pulled my switch apart to install the original keyed cylinder, I noticed that the brass contact on the inside of the switch had melted about 1/16" into the switch case. Don't know if that means anything but it was odd to say the least. Good news is that I haven't had problems with it since.
Tourer
Joined: Nov 2007
Posts: 491
Likes: 5
From:
I just experienced this exact same problem today...stuck in rush hour traffic on the interstate...bike died right in the lane and nowhere to go, no shoulder....lucky a DOT guy stopped for me and got me off the road without getting myself killed. In checking things out I had no blown fuses, but had no lights, ignition didnt' work, nothing...but I remembered this post, so I removed the console and sure enough the ignition contact terminal was burned right thru. I switched around the plug and therfore got power from the accessory side, and voilet!! the bike started! amazing... I too have a thundermax ECM, and you can bet, once I get a new switch and harness I'm yanking that thing off and putting my stock ecm back on and will decide what to do about tuning. My tmax also has the problem where the speedo will just lose contact with the ECM for no reason, and Zipper's has yet to find a fix for that.... I'm done with Tmax.
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Ultimate HDF Member
Joined: Oct 2007
Posts: 5,257
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From: Leander Texas
well if you sell the thundermax on the hd forums you will get about $450 delivered. i still run mine and for the little problem it has i am happy with it. are you getting the switch from ebay. good switch and much cheaper than Harley part.
I could not replace the plug so i got crimped connectors. i think i will solder them to the terminals before my trip to sturgis.
I could not replace the plug so i got crimped connectors. i think i will solder them to the terminals before my trip to sturgis.
'03 Heritage Classic
Same thing just happened to me. I have the stock ECM. I broke down on the highway in West Texas on my way home to California. I was able to scrape enough crud off the connectors to get it fired up again. I got all the way to Las Vegas before it finally crapped out for good. The temperature was over 102 degrees every day on this trip.
The dealer in Vegas told me it was caused by connections getting loose. Fortunately I have family in Vegas to stay with. The bike is in the shop as I type and won't be ready for a week. They had to order an ignition switch that is keyed for my bike. (I wanted it that way) They also had to order a connector for the fuel pump because it was fried as well. (Yes, they showed me)
This will be my 3rd ignition switch! They seem to last me about 4 years. I have 54,000 miles on my bike now and keep it in the garage. It is well cared for. Harley needs to take some responsibility and make a better switch.
So here I am.... Stuck in Vegas and I don't even gamble.
The dealer in Vegas told me it was caused by connections getting loose. Fortunately I have family in Vegas to stay with. The bike is in the shop as I type and won't be ready for a week. They had to order an ignition switch that is keyed for my bike. (I wanted it that way) They also had to order a connector for the fuel pump because it was fried as well. (Yes, they showed me)
This will be my 3rd ignition switch! They seem to last me about 4 years. I have 54,000 miles on my bike now and keep it in the garage. It is well cared for. Harley needs to take some responsibility and make a better switch.
So here I am.... Stuck in Vegas and I don't even gamble.
Outstanding HDF Member
Joined: Apr 2010
Posts: 2,477
Likes: 14
From: Western MD
from my experience whenever you see a electrical connector melted like that, it is due to a loose connection. the heat buildup from the arcing across the switch terminal to wire terminal is incredible and melts the plastic which in turn gets in between the the two terminals causing more resistance and more heat. eventually you end up with what the OP posted. its been happening for years in ford explorer blower motor switches/harness and honda has a recall on the ridgelines with their blower motor connectors coming loose and melting out the harness.
Banned
Joined: Mar 2011
Posts: 429
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From: Shitty City, Chicago
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Yes you can keep your key. I just swapped out mine. I found a youtube video that showed how to do it. Can't find it now but it was an easy swap. Now I just need to get a backup ebay switch to keep with me.
Stellar HDF Member
Joined: Dec 2005
Posts: 3,231
Likes: 106
You got a bad switch then. Make sure the grips are tight in the new connector. Also make sure there is contact grease in it.
