04 Ultra Ignition switch ?
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From: SE. Michigan
04 Ultra Ignition switch ?
Riding home from work today the engine just dies after pulling away from a light and going through the gears, doesn't die out completely and takes off again without a hitch, I'm thinking maybe I hit the kill switch or something ? Had a stop on the way and when I come back the bike I turn on the ignition switch hit the run switch go to hit the starter and Nothing ! turn the radio off and I notice that I don't here the fuel pump when I hit the run switch, then I notice I have no Headlight ether, radio and gauges are all lit up tough ??? so I turn the big **** switch back and forth a few times and the headlight comes on and I hear the pump and she fires right up, I get home with out any hiccups, but when I go to start it later, same thing. I fool around with the main ignition switch ( back and forth a few times ) and everything comes on, it fires right up. I'm thinking the big switch under the **** is failing, Anyone else had problems with the main switch, Is this a common thing ? I called dealer and they had 4 in stock and at $70.00ea. that seems like a lot of switches to have in stock, unless they sell a few of them.
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From: Phoenix '53, '88, '09 Big Twins
Don't know by 04 but that switch on the Evos was a problem to anyone who increased lighting in the front end- the lighting and ignition all go through the same switch contacts- extra current ( amps/watts) would burn the contacts, as they burn and carbon up resistance increases, the contacts get hotter and complete failure results.
Many Evo riders managed to get free replacement under a service bulletin
so what the part number on that---- is it the same Evo era switch?
have You increased lighting load?
mike
Many Evo riders managed to get free replacement under a service bulletin
so what the part number on that---- is it the same Evo era switch?
have You increased lighting load?
mike
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From: Phoenix '53, '88, '09 Big Twins
I guess this is the part number for your 2004
71640-99
so not the evo era switch
You should ask H-D or enter your vin at website and see if there was a recall or service bulletin
Mike
71640-99
so not the evo era switch
You should ask H-D or enter your vin at website and see if there was a recall or service bulletin
Mike
Last edited by mkguitar; Aug 23, 2011 at 10:16 PM.
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From: Roswell, GA
I replaced the ignition switch on my '04 a year or so ago. Easy to do and it fixed the problems you describe. The switch is an unusual contraption with ball bearing like rollers that seemed to wear out the ramps IIRC.
My dealer had it in stock, so it's probably something that wears out; in my case, after many cycles of operation of 60K miles of many short trips.
I was surprised how tight the new switch operated compared to the slop in the failed switch; slop that I never noticed but obviously evolved over the 5 or so years of operation.
MK gave you the right p/n.
Carl
My dealer had it in stock, so it's probably something that wears out; in my case, after many cycles of operation of 60K miles of many short trips.
I was surprised how tight the new switch operated compared to the slop in the failed switch; slop that I never noticed but obviously evolved over the 5 or so years of operation.
MK gave you the right p/n.
Carl
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From: SE. Michigan
Thank you both ! I have 45,000 mi. (lot of short trips too) no extra lights or anything Just worn out I figure, Cause sometimes you can turn it on and everything will come on except the headlight and it won't crank, if the head comes on, Fires up no problem, will get the new switch today. Again Thank you !!
Road Warrior
Joined: May 2008
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From: Salt Lake City, UT. Dushore, Pa.
Thank you both ! I have 45,000 mi. (lot of short trips too) no extra lights or anything Just worn out I figure, Cause sometimes you can turn it on and everything will come on except the headlight and it won't crank, if the head comes on, Fires up no problem, will get the new switch today. Again Thank you !!
Road Warrior
Joined: May 2008
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From: Salt Lake City, UT. Dushore, Pa.
What did you use to get the connections apart, manual shows HD-45961 which naturally they don't loan out. It looks like I could just grind some bracket material to make one but what worked for you?
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From: SE. Michigan
07 must be different than 04, I only had a little bit of trouble with getting the big **** where the key goes in, to come out. read the manual for the 10th time and finally it popped up and out it came, the rest was easy to do, did not need a special tool at all ? whole job done in about 1/2 hour. Leaving in the morning for a nice long weekend, should see around 800 to 1000 miles on this ride, hope the switch was the problem, So far so good ! Ride Safe All !!
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From: Roswell, GA
07 must be different than 04, I only had a little bit of trouble with getting the big **** where the key goes in, to come out. read the manual for the 10th time and finally it popped up and out it came, the rest was easy to do, did not need a special tool at all ? whole job done in about 1/2 hour. Leaving in the morning for a nice long weekend, should see around 800 to 1000 miles on this ride, hope the switch was the problem, So far so good ! Ride Safe All !!
Safe travels, 62pan.
Carl
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