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'02 FLHT won't start sometimes

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  #21  
Old 03-20-2015, 08:30 PM
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Originally Posted by dyna07custom
So you have 2 Intermittent issues sometime wont crank and sometime cranks but no spark. I think Harley Cruiser has sent you in the correct direction and the relay is where you need to start, that is as long as you are sure your battery and cables are all good.
In all honesty I think he probably has only one problem that is causing both issues.
Just need to run it down.
 
  #22  
Old 03-24-2015, 06:40 AM
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I haven't solved it yet but I am pretty confident the it's the socket for the ignition relay. the problem has happened twice since my last post. both times there was 12v at the ignition fuse but not to the ignition relay. I have identified the wire from the ignition fuse to pole 86 of the relay socket. I have not checked it for continuity but I will. I have the next 2 days off so I will mess with the bike some more.if I pull the relay out of the socket a 1/4" or so it starts to work. I have a little thin file in my toolbox at work. I'm gonna bring it home and clean out the sockets for both relays and put some dielectric grease on the relay poles. hopefully that solves it.
 
  #23  
Old 03-24-2015, 06:54 AM
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It's not a bad idea to replace the relay napa sells those for about eight bucks, they are called micro relays.
I like spray electrical contact cleaner. And like you say pack the socket with dielectric grease. At this age of you bike you need to do all of your conectors.
Especilly the one between the run switch and the starter relay.
 

Last edited by Harleycruiser; 03-24-2015 at 07:05 AM.
  #24  
Old 04-25-2015, 09:04 AM
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Originally Posted by chopped7
I haven't solved it yet but I am pretty confident the it's the socket for the ignition relay. the problem has happened twice since my last post. both times there was 12v at the ignition fuse but not to the ignition relay. I have identified the wire from the ignition fuse to pole 86 of the relay socket. I have not checked it for continuity but I will. I have the next 2 days off so I will mess with the bike some more.if I pull the relay out of the socket a 1/4" or so it starts to work. I have a little thin file in my toolbox at work. I'm gonna bring it home and clean out the sockets for both relays and put some dielectric grease on the relay poles. hopefully that solves it.
Did you ever figure out the problem?
 
  #25  
Old 04-25-2015, 09:48 AM
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It's not grounding inside the starter, you could take the side cover of starter off ad try to clean it up with a wire brush, but it'll happen again replace the starter you won't have a problem
 
  #26  
Old 04-25-2015, 09:49 AM
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As long as you have power to the green wire plugged into the starter use a test light to make sure when the start button is pressed it should light up
 
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