** Warning: Long Post! Please, don't be afraid though, I could use your help! ** All: Long time no post! Real life has come along and kicked me in the backside the last couple of months. Some of you might remember that around January of this year I was posting about a "no start" situation with my 1989 FLTC. If not here is a link to the thread here on HDTimeline: 1989 FLTC Not Starting Intermittent Problem - Harley Davidson Community Well, for the last few months the old bike has been running beautifully. I've taken her on several very long trips, put several thousand miles on it and it hasn't missed a tick. It started up, first time, every time. I was honestly quite impressed with the old thing. Unfortunately ... that all came to an end last week. Everyone was so very helpful the last time around (without everyone's help I doubt I could have fixed it), so I'm back hoping to bounce this off some of you more experienced mechanics out there. I'm quite frankly a bit stumped. How the Problem First Presented Itself I was on short trip to run an errand (less than 20 mi.) when on the way home I got stuck in horrible bumper to bumper traffic waiting for a light to cycle enough to get through. The bike had run fine on the way out, and on the way back up to this point. For what it matters, I'm in Orlando, FL and it's summer. It was hot (around 95 degrees out). After sitting at the light for several cycles (10 minutes or so), I went to give it a little throttle to move up with traffic, when the bike coughed hard, and stalled. I clicked it in to neutral, and went to restart it. It turned over, but wouldn't kick on. It did the "RRRRrrrRRRRrrrrRRR" (yeah, go ahead and laugh) sound. I switched off the ignition, and the start/stop switch, turned it back on and tried again. This time I was rewarded with the loud "click" of the starter solenoid engaging but the engine did not try to turn over. This was the same main symptom I had from the previous thread (see link above). I pushed the bike off to the sidewalk and tried it a few more times. Most times I received the "click", a few more times I got the "RRRrrrRRr", there didn't seem to be a reason for one or the other. I eventually tried to kill myself and pushed it the last mile home. 1200 pound bike + 95 degree weather + 1 idiot = I thought I'd die. But I got it home. How it's Presented itself Since Since I've gotten the bike home it has mainly presented itself with the same "click" I've come to really, really dislike. However, on several occasions, or usually when I attempt to jump start the bike from my truck (I know not always a good idea, but it helped troubleshoot last time) I get the "RRRrrrRRR" engine turn over, but no attempt at starting (no spark). What I have Tried So Far In an attempt to work through the problem, I have tried several things to isolate it, with more or less success as you'll see below. I will try to give a complete list here, but I'm sure I'll miss something. 1. I tested the voltage on the battery. I also slow charged it to full just to be sure. It reads around 12.5 volts. I also had it load tested at the local auto parts store - just to be sure. It passed. 2. I've verified that all wires, and connections replaced last time are still in good working order. They all appear fine, and voltage tests across all wires were good. Voltage drop was around .2 to .5. 3. I tested the starter relay, and found it was fine. I did however replace it with a brand new one I had on hand "just in case" to make sure that wasn't the issue. 4. In testing the wires, and relay I noticed the main circuit breaker (two post, 15A) was getting pretty hot. Since I know this could mean a bad connection I cleaned and reseated the wires (red wire that runs up the harness to the console, black wire that runs from the post on the starter, and a little black wire that runs to voltage regulator). After reconnecting all the wires it was still running hot. Resistance tests showed it was under .4 however I replaced it regardless with a spare. The breaker (and associated wires) are no longer getting hot. 5. I began inspecting the wires that make up the starting circuit and tested the red wire up to the console. I found that the circuit breaker in the console where the red wire connects (also where the red wire from the ignition switch was also getting hot. I replaced that breaker as well. It is no longer getting hot. Voltage tests read fine. Here are some symptoms I'm currently experiencing I could use some help with: 6. While working in the console I noticed that the breaker next to the one I replaced was also getting very hot. A voltage test read fine, but it was burning up. This is the breaker that has the wires from the start button and start/stop (kill) switch on the right handlebar attached to it. I traced the grey wire from the breaker to the wiring harness and found that the grey wire was also very hot (either from being connected to the breaker or vice-a-versa). 7. I cleaned and reseated the wires on the breaker. Disconnected, cleaned and reconnected the wiring harness connector. It still got hot. 8. In testing where the bad connection might be, I disassembled the switch housing for the start button, and start/stop switch. It is a newer switch (replaced at some point prior to me owning the bike). It appears visibly ok.