I got my '94 ultra in 10/93. My switch failed 5/94. The bike cut off while driving down the road, just like you said, someone cut the switch off. I contacted hd, they said it wasn't covered. I bought a new switch, and installed it myself. It hasn't failed since. They kinda took me since it wasn't the updated switch with the relay that they sold me.
I got the recall several years ago, and have taken it to be done twice. Neither time has it been completed, and my inner fairing was wired wrong both times. The first time, they called and said there was non covered work I'd have to pay for. (Probably their wiring confusion...).
The second time, they ruined my radio retaining clips... to the point I had to force them out from the inside of the fairing with long needle nose pliers. It's critical to get the stereo out, and you can't with mangled retainers locking it in place.
I took the old switch apart carefully, and it looked like it was lubed with white lithium grease. Only it must not have worked, because my contact area was full of brass or copper filings, in the grease, bigger than sawdust. My guess is it shorted internally through the dust I saw in the contact lube. The second one installed by me in '94 still works great.
Location: The base of the Colorful Colorado Rocky Mountains!
Posts: 311
Re: '95 FLHTC Ignition Switch Recall
That is good information to have. I went to start it again hoping that it would start (without the switch recall) Click, click, click. OK I can take a hint. It is my hope that Sun Harley can get the switch out and replaced without any problem. I figure if I can build a B1-B Bomber I can fight my way around the charging/electrical system. But giving the pros a shot first. I would like to have it up and running for the Veteran's Day Parade.
Oh yea, I am positive you can do it, the difference is being versed in doing it.
Kudos to you for going with an older evo. I think you'll be happy, too. I am surprised by how many people recognise that my '94 LOOKS new, but is far from it.
If you need advice or an opinion, don't hesitate to ask, and good luck...
Location: The base of the Colorful Colorado Rocky Mountains!
Posts: 311
Re: '95 FLHTC Ignition Switch Recall
Update.. Picked up the bike from Sun. It starts and everything! Actually it even may be charging though it does not go above 13 volts at highway speed. But I've started it and stopped it and it seems to be working. Of course I will need to actually put the fairing wiring back where it belongs. And they said it needs some intake work like manifold gaskets, carb seal set and carb to manifold seal. Funny, it seems to run a bit more rough than it did when I took it in there. I even have my battery tender connected to it-just in case...
Location: The base of the Colorful Colorado Rocky Mountains!
Posts: 311
Re: '95 FLHTC Ignition Switch Recall
Just a quick note: Since getting the bike back from Sun Harley it has not failed to start. And as I suspected with the bad ignition switch, it was also draining the battery somehow. Now when I ride it stays steady at 13 volts charging. It sorta drops off line at idle but anything above idle sends 12-13 volts to the system. If the stator or VR go out I will replace them with the 3 phase, Compufire kit. Just checking in... Thanks. Kempo
Kempo, I did the 3 phase CompuFire on my 87 Heritage in August...the difference in charging is worth the effort...no more wondering if the bike has the juice to start. I put in a 48 amp system vs. my factory 22 amp. WOW is all I have to say!
Location: The base of the Colorful Colorado Rocky Mountains!
Posts: 311
Re: '95 FLHTC Ignition Switch Recall
Quote:
Originally Posted by Trigger87
Kempo, I did the 3 phase CompuFire on my 87 Heritage in August...the difference in charging is worth the effort...no more wondering if the bike has the juice to start. I put in a 48 amp system vs. my factory 22 amp. WOW is all I have to say!
I have been looking at that system too. It pumps a charge in earlier in the RPM range and has a higher output at highway RPMs. Of course this system is like, what, 500.00? I saw it in JPCycles. But I have to admit having all that voltage through the RPM range sounds appealing. Worse came to worse I could also use it for an welder! I read somewhere that pumping 45 amps into a system designed for 32apmps can be hard on breakers, wiring, etc. Some people have changed their breakers/fuses for 50 ampers only to char up their wiring.
If I had to put any big money into the bike other than the rebuild I want to do, the compufire would be my first choice. That would give me a chance to tear off the primary and make sure there is an upgraded tentioner on the primary. Cha ching... Ok since I am in there I should look at seals and clutch! I need a better job!
I ordered the CompuFire through my HD dealer...got it for $386.00 (with tax). I have had no problems with breakers or wiring. I also upgraded to self cancelling turn signals and run/turn signal/brake light module, with LED lights. I'm running hi-comp pistons, so the peace of mind with the charging system andthe added visibility was well worth the bucks!
Location: The base of the Colorful Colorado Rocky Mountains!
Posts: 311
Re: '95 FLHTC Ignition Switch Recall
It is amazing that a dealer would be cheaper than internet/mail order. For that price I could rationalize purchasing this system. I have heard nothing but good things about it.
Re: '95 FLHTC Ignition Switch Recall 
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