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[admiralcad]

 A couple months ago I was riddin my 05 Ultra and the stereo went off and I herd a terrible noise, scared the bejesus out of me. I killed the engine and rolled of the road, when I flipped the kill switch back on the starter, started cranking without me pushing the starter button and when the bike started, she just kept cranking. I shut it off and flipped the start button a dozen or so times, and when I turned the kill switch back to run, it was fine, bike started and ran fine, no problems. Until last week, riddin and it done the same thing, I like to never got it to stop this time but finely did.
 I'm sure it's a ground inside the switch housing, but I have never had one of them apart. When I mentioned that I was going to tear into it my riddin buddy's ALL said DON'T do it dude, take it to the dealer.
 Now I ain't a mechanical genius, but I ain't stupid ether, and I can't stand the thought of taking my bike in to let them charge me $70 per/hr to take out a couple screws, put a peace of shrink tube over a bare wire, and tell me that took 2.5 hrs. But I don't want to get into something  that I going to cause more problems than I fix.
 The things I've been warned about are,
1. The stereo control buttons breaking off in the switch, ruining the switch.     
2. The break light switch breaking when I pull it apart.
3. The wires getting pinched when I finely put it back together after I go to the dealer an buy back everything else   that I tear up fixing it.
 Now my question is, has anyone on here had this problem, and if so, did ya fix it yourself or take it to the vet.
Is it really that hard (DANGEROUS) to take the switch housing apart without totaling the bike.
 I'd really be grateful for any input.

[Firechief2]

When I had similiar problems on a previous bike (BMW) the problem was a selonoid that stuck (welded the contacts together?---because of low cranking power of battery ?). Hopefully others with more HD experience can add to this but I wouldn't think that it would have anything to do with the switches at the handlebars.

[Rooster]

Welcome to the site. Hope you find your gremlim soon. Firechief2 might be on to something.

[REGGAB]

Sounds to me like you have some spark chasin' to do.  Sure, you can open up the switch housing and take a peek, but as has been previously mentioned, the problem is likely at the solenoid.  There are myriad disconnects between the switches and the starter solenoid though.  If you have a service manual, pullout the applicable harness wiring diagram and chase the starter circuit with a highlighter.  Then physically look at all the disconnects on the wires you've highlighted and see if you can see anything that might be shorting to ground.  Highly unlikely a meter will be useful since this is an intermittent spark gremlin, so you'll have to hunt it down visually.  Best to ya, and let us know how it works out.

BTW, Welcome to CVOHarley.  Doggone glad to have ya here.  

As an aside, I might be able to help you out with some wiring diagrams and further guidance via email if the need arises.

[Hoist!]

It happened to me on my '85 FXWG. Had to disconnect the battery to stop it. Turned out to be a short in the starter itself.

Hoist!

[hd-dude]

First off welcome to the site,

Second, to answer your question the most likely culprit will be the starter switch itself. I had a similar problem child a few months back that took a while to find. You'll need to meter the resistance across the switch and if it is "infinite" when not depressed and "0" when pressed. The one the I had an issue with had varying resistance across the switch when it was not depressed. The symptom of the stereo turning off when it happens is significant as when you press the start button the accessories are shut off via the start relay.

[Twolanerider]

First off welcome to the site,

Second, to answer your question the most likely culprit will be the starter switch itself. I had a similar problem child a few months back that took a while to find. You'll need to meter the resistance across the switch and if it is "infinite" when not depressed and "0" when pressed. The one the I had an issue with had varying resistance across the switch when it was not depressed. The symptom of the stereo turning off when it happens is significant as when you press the start button the accessories are shut off via the start relay.

Jim, is that a problem that like others in the handlebar switches might be cleared by a good spraying of electrical cleaner and blowing the crap out of it?  Or is it a failure more likely to require a new switch? 

[hd-dude]

Jim, is that a problem that like others in the handlebar switches might be cleared by a good spraying of electrical cleaner and blowing the crap out of it?  Or is it a failure more likely to require a new switch? 

New switch. They are suppose to be a sealed unit. What happens is that it allows some voltage (based on the resistance)to the relay. The relay coil is trying to be pulled by the lower voltage and will eventually kick in which enguages the starter. The bike that I had the issue with ended up grinding the starter ring and pinion gears to bits. It took a while to trace it down to the switch but finally found it. 

[Twolanerider]

New switch. They are suppose to be a sealed unit. What happens is that it allows some voltage (based on the resistance)to the relay. The relay coil is trying to be pulled by the lower voltage and will eventually kick in which enguages the starter. The bike that I had the issue with ended up grinding the starter ring and pinion gears to bits. It took a while to trace it down to the switch but finally found it. 

That makes sense.  Just never had one fail so had never taken the opportunity to look at that particular switch closely.  Thanks.  Will make some day's future troubleshooting just that much easier.

[Firechief2]

Just re-read my earlier post ----duh ---- I meant to say "relay" not "selonoid".
I don't have my manual here ---- can some-one tell us where the starter relay is located on this model ?

[hd-dude]

Just re-read my earlier post ----duh ---- I meant to say "relay" not "selonoid".
I don't have my manual here ---- can some-one tell us where the starter relay is located on this model ?

It is under the seat just behind the battery. It sits in a rubber boot in the frame. You can see the top of it, it is a standard Bosch type automotive relay.

[Ironhorse]

I had a similar problem. It was pinched wiring. Are your wires run internally, or outside the bars? Mine were pinched where they ran inside.

Mark

[AXIL]

 my guess would be a relay. you have a starter relay and a system relay, i would replace them both there cheap. axil

[Admiral]

Welcome from Texas                                                         
 

[BIGDOG]

Happened to me once also. Just took my finger off the starter button . fixed it right off