Another update (hopefully the last)...
So I got a call from the Shop Foreman today at the dealer (Harley-Davidson of Edmonton) working on my bike. He said they went over my bike and did a bunch of electrical tests and more test rides but still couldn't reproduce the problem. He said he then called Deeley Canada, which is the exclusive Canadian distributor to get an opinion from their people. They didn't say anything that hadn't been tried already so they setup a call with the Shop Foreman and Milwaukee who also spoke with guys at the factory about the problem. H-D advised that a while back they had a bike with a similar problem that ended up having a faulty Kill switch (credits go to Bodeen and TQuentin1 for suggesting it first, we have some smart people here). After it was replaced, the guy never had the problem again.
Before replacing the Kill switch they had also gone over all the electrical connections on the bike and tested them. He said there was also a bunch of corrosion on most of the connectors (everything from inside the fairing to under the seat) so all connections (even those without corrosion) were cleaned up. I asked why there would be so much corrosion on a 6 year old bike. If there's one thing I'm guilty of, it's not keeping my bike as keen as I should. When I wash it, its with a pressure washer but surely I'm not the only one. I would think Harley has half decent protection against water since it's an vehicle that will see all kinds of weather (even snow for those unfortunate enough).
He said that the Moco also advised that if it happens again to try turning on the high beem and seeing if the light comes on as apparently it's on a different circuit. Not sure what that will tell them but hopefully the problem won't return, at least while I still own it, but I wouldn't want someone else to risk their lives with it either.
The only bad news is the cost associated with all of it. The Foreman said they put between 8.5-9 hours into my bike but they want me to pay 4.5 hours of labor which works out to $495. That's kind of painful but hopefully this will be the end of it all. They said the Moco doesn't pay for them to diagnose problems, just replace the parts. I can kind of understand that. I used to work in I.T. and it was the same way. We got a flat rate to fix it no matter how long it took to resolve. Sometimes problems can be a real bugger and I really appreciate all the effort that they put into it. Much more than I can say for the dealer I bought my bike from when they looked at it a few times. Needless to say they have a new customer. They're a lot father from home than my usual dealer but the fact that they gave a crap and put all that work in, a lot of it for free, means something to me as a customer. May the rest of my riding be trouble free (at least from this problem). I won't be able to pick her up until Tuesday due to my work schedule but I'm really looking forward to riding her again.
Thanks H-D of Edmonton and everyone at HDtalking who offered suggestions and advice. There is a great group of guys here and the experience of everyone is invaluable.
FLHTrider08
