I have a 2004 Ultra Classic, every now & then I hit the start switch & nothing happens. I did replacethe start switch assembly, but I had same problem today.I get it started by running a wire from pos. lead to green wire going to starter. Any help appreciated...

 

Try to wiggle/ jiggle / move it slightly from the normal run position while hitting the starter button. These ignition switches will fail like that and not start. Mine did...

 

Your starter coil is the next place to look.

 

sounds like the relay to me if you are bypassing it and it then works. that green wire goes to the starter relay in the fuse box. there are actually a few of the same relays in the box you can shuffle them around or just buy a new one at any auto parts store to check it.

 

your jumper wire bypassed the starter primary circuit- it showed that the starter, solenoid and the ignition system ( and ign switch) work

so you are looking at the start switch, start relay or the wiring connections which make up the primary circuit

as above, swapping in another relay is easy -start there.

you could have a dirty wire connection, disconnecting wiring, cleaning and putting back together could be a fix

think about your previous repair- esp if you soldered in a new switch. soldered joints do not hold up well on a bike due to vibrations.


an easy easy fix is replacing the solenoid end cover with one that has a manual plunger- about $40 from a catalog house.
to start you push on the plunger...this bypasses the starter primary circuit

mike