| Author | Message | ||
     Backroad_hog |
I was on the way home today, and all the sudden my Uly started cutting out and the all the gauges and lights were cutting on and off. and then it died all together. the battery gauge showed good charge. but no instruments would come on. I started checking for short and I pressed on the fuse box and the gauges came back on, but if I started the bike every thing would cut out after a few seconds. After I got the bike home ( had my son bring the truck ) I narrowed it down to the key switch relay in the fuse box. I pull the relay and had some burning and melting on one of the spades. I have ordered a new relay, but I suspect that the real problem lies within the connection in the fuse box itself. Can anyone tell me the secret handshake for getting the fuse box out with out breaking any thing? The workshop manual is no help on this I have tried to release the 2 plastic tabs from the metal hooks on the right and lift up, but to no avail. Any help is appreciated  | ||
| Hughlysses |
BH- It's not hard to get out once you figure out the trick. I had to remove mine to do the Comfort Kit install ~1.5 years ago. You see the place on the right side of the fusebox where the tabs are, right? IIRC, you take a flat-blade screwdriver and insert into the rectangular socket on the left side of the metal tab. Push the plastic tab to the right and pull up. Once you figure it out, it'll pull right out. BTW- those relays are common with the air conditioner relay on some early/mid-2000 model Ford cars. If you can find a smart parts man, you can pick up a replacement at your local auto parts store. | ||
| Uly_man |
It sounds about right. This relay is, it gets a bit of a hard time, also known to fail in itself. While you have the fuse box out I would, if you have not done it, file off the paint on the Earth point, from the Sub frame, for a good Earth connection. See picture.  Its a known problem with the Uly for running/starting issues and my even help your bike. (Message edited by uly_man on January 09, 2011) | ||
| Backroad_hog |
Thanks for the assistance, I got the fuse box out and I removed the spade and it was not making good connection I re-sprung the tabs in the spade, and I may make some small shims like I have in my 77 connector to insure that good contact remains. I have taken the earth ground off and sanded down both of the connector ends to the copper base. One caution though, this plastic is brittle, and I have had to use super glue to get the connector retainer tab back in place. I will insert some silicone sealant once I put the relay back in, to make sure every thing stays in place I will finish this once the relay comes in.  | ||
| Uly_man |
Just to be clear Hog. The Earthing problem is the paint on the sub-frame battery/loom mount face, which needs to be removed back to metal, and just cleaning the wire lugs is not enough. What happens is the paint causes a bad electrical resistance and this effects the starting, charge rate and ECU/ECM. It took me two years to find this one and once I did the bike has run perfect ever since. | ||
| Backroad_hog |
Uly_man This would entail removing the battery and the metal bracket that supports the battery correct and then sanding off the powder coat on the sub-frame itself? | ||
| Ulyrpg |
I had to remove the tray and clean the paint to get a good ground on my ULY too.Since then no more stall outs or hiccups. The Lug that threads into the frame was melted at the threads from the heat created by the intermittent contact. The bike is still under warranty but the dealer could never duplicate the concern, it was intermittent and very annoying. Like Uly man said it took a long time to diagnose because it was so intermittent. It is a solid fix! |
