OK, I'm scared...

[The Rook]

Almost all the way home from work today(25 miles) and my 96 Sportster with 39k miles 'pops'(I think it was a pop out the exhaust) and then the thing goes dead while I'm doing about 45MPH. It started again without a problem but it seemed like the key wasn't fully foward when I reached down to start it. It was just as I was going into my reserve tank. Could that have been the problem?

Also I felt the oil tank thinking that it may be overheating(I live in Arizona) and the tank was almost too hot to touch.

Any ideas?

As always thank you in advance.

 

[glider]

If the ignition key isn't fully in the run position, it could have caused what you experienced.

 

[The Rook]

WOW, these are fast replies.

I just got back from looking at the ignition, when the key is in it is real loose and wiggly. How do I tighten it up, any ideas?

Thanks for all the replies.

 

[glider]

Replace the switch

 

[The Rook]

OK, now it 'pops' when I start it up. :17:
After that it runs fine...one single 'pop' as it's starting. I bet these are related.

 

[glider]

Check for any intake leaks. Sporties are notorious for popping back through intake.

Take a look here and drain the carb float bowl of a few ounces of fuel periodically.

Poor Performance With Carb Models - Harley Davidson Community

 

[HarleyHarry]

Do you have a large keyring? Just thinkking that you may be wearing out the ignition lock if you are. Sporties vibrate and a heavy keyring does not do a lot of good to the lock.