My 2005 Ultra has on going issues with start ups, hot or cold

Its fitted with a brand new Thundermax module (recently supplied after other issues)

Recently while trying to start the bike with the right side cover off, i noticed the system relay was warm

I swapped it for another spare i had & the bike fired up straight away!

After a few more stop / starts, it did the same thing, swapped the relay again & started straight away

Any suggestions as to what might be causing this problem? Anyone had this issue?

The bike does run & ride perfect once started.....

thanks

Stator issues possible ?

Something is holding the relay on... Or perhaps it is supposed to be on.

charging ok at 13.7-13.8 volts so i've ruled that one out.....

from what i see its meant to have a constant power supply from the ECM which it does but somethings making it overheat

i've just grabbed another relay to try anyway

Sounds like it might just be the starter relay, you tried another second hand one (so it could have been iffy). Why not try a "brand spanking new one" with the correct amps. You oughta be able to buy one from repco,sparco etc.For very little cash money.

Just did the same thing on one of my bikes and it fixed the problem instantly.

This finally got to me.....

I trailered the bike thru to Scotty Nation at Tassie Choppers in Launceston.

After a few days he eventually discovered the problem.....

Seems HD released a Service Bulletin (M-1185) for 2006 1450cc Big Twins & hard starting when fitted with 8 degree spray angle injectors.

The solution was to fit the later 25 degree injectors.....

Bike now starts & runs like it should, thanks again to Scotty Nation (highly recommended)

 

Thanks for coming back and informing us of the outcome ..... definitely not one I would have thought of ..... Good to have a workshop like that nearby .....

I remember when had  my 2006 Fatboy at the time of release of Injectors 8 or 25 .. Had a win, mine were 25 degrees.