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i take it its carb. after it warms up to operating temps does it stop the sputtering? thats just a HD CV carb doing what it does til hot. Im not talking a 2 min warm up and off u go im talking operating temps of 200 plus. Is the carb an S&S? Your going to have high rpms til the temp kicks it down if its injected
It sounds like you have a short in your start button wires, this could be caused by having custom bars with internal wiring. The wires chafe, touch, and it bypass's the button altogether. I would check continuity at the connector on the 2 wires of your start button and see if it changes whether the switch is depressed or not. If you have continuity both ways, you have a short. You should not have continuity unless you depress the button. If all looks well, re-post.
test or replace your ignition module,and you might find the actual prob by accident the connector for the module sometimes with age lose or only have intermittant contact.a can of electrical contact cleaner should take care of it but those symptoms scream ignition mod dont know why hd dealer couldnt find it but they dont put their best techs on older bikes
This is generally a loose or broken ground wire that causes this. It could also be in the switch, you can test the switch by pulling the **** shell apart exposing the switch, and using a piece of wire, jumper across the connection wires. If you can get the signal to light this way, then it's a faulty switch. It doesn't need to blink when jumpering it, just light up.
Check your wiring for continuity. Mine did the same on the Fatboy - found a broken return wire by the right Handlebar switch when I opened up the switch gear housing on the bars. Bit of solder, heatshrink and good as new! (my problem light was on the right side so check the left side on your first - was a white wire with orange stripe I think, should be easily visible from the indicator switch inside). All the other lights worked fine. Maybe an earthing problem?