A group of us had just pulled into Cherokee NC off the Blue Ridge Parkway and decided to take a break along a rest spot. After deciding what twisty road to attack next, I went to start my '04 1200 and zip, nadda! Lights bright, horn works, but nothing from the starter. Fuses OK, everything seems right. After five cardiac-arresting attempts at bump-starting (use 4th gear), she fired up and I headed straight to a shop near where we were staying.

The mechanic (with a good reputation) poked around and the only conclusion was it must be the little starter relay. A call back to the dealer in a not-so-near town and ordered a new one. One of the gang rode off to get the relay (and got soaking wet along the way) and he returned a couple hours later with the new relay. Ach!! Different pins. Mine had 4 pins but the new one had 5. A call back to the dealer who insisted it was the one called for in the book. Being late, we gave up and waited to take my relay back to the dealer the next morning to show how mine differed from what he sent. Sure enough, his parts book called for the one he had sent.

This is important for you '04 owners: seems HD had switched to a 4 pin relay for the '05 and later Sportsters but did so in late 2004 without making a note of it. Well, at least I now knew I had a late '04. So back to the shop with an '05 relay and plugged it in. Aaaarg! The new relay clicks away as it should, but still no starter.

This is important to all you late model owners: After poking and prodding about, we pulled back the oil lines on the right side of the engine and revealed a little white molex plug attached to the bottom of the selenoid. Well sort of attached. Nothing much holds it in there and it was loose. Pushed it in tight and the bike started right up. Obviously that was the problem from the get-go. A whole day of riding shot because of a dumb plug.

One other thing I learned from this experience: HD doesn't use any sort of electrical grease on connectors like most metrics do, and they all tend to corrode. This bike hasn't been wet except for occasional washings and caught in one short rain storm. Clean and lube your electrics.

 

Good info, I'll check and see which relay I have beforehand.

 

Same thing happened to me (except for the whole group ride scenario).

I trailered (sp?)it back to the dealer, and after a little testing and head scratching -said little white molex plug attached to the bottom of the selenoid had worked loose. The dealer put a longer wire on the attachment for me.

 

I am glad that you got it back up running. The 5 pins relay probably has an additional 87a normally close circuit for other electrical devices. In case you are stuck next time, jump pin 3(30) and 5(87) on the starter relay socket, you can send power to the starter directly. I guess any electrical connector has to be greased to prevent moisture.

 

Iwashed my Ultra monday and then it would not start. Dealer made a service call to pick up the bike. Hefixed it simply by pulling hat wireoff and putting it back on. Best dealer in the world, drove about 30 miles and didn't charge me a dime. Thats exactly why I buy local and pay their price.

 

When I wash my bike, I cover the air cleaner, speedometer and coil, I use light pressure water just enough to rinse the soap, I always worry about the electrical parts get wet.