03 big dog chopper

Energy One

Alaska Jay

New Member
I’m having starter problems I’ve replaced the battery and starter module i just bought the starter last year so I rebuilt the solenoid and still it try’s to start for a second and then the starter solenoid disengages, and it just spins any suggestions
 

Mr. Wright

Knows some things
OK, I need you to check this. There is over 50gs of vibration at the transmission on these bikes, and because when starting this terminal gets hot.
IMG_20221208_113347.jpg
Disconnect the battery, and take the cover off the back of the solenoid .
IMG_20221208_113531.jpg
Remove the plunger and spring. Clean the contacts while your in there.
IMG_20221208_113541.jpg
Take a small screw driver and gently stick it between the wire at this solder joint, and see if it is broke loose. This is a common problem on the 03-04 bikes.
IMG_20221208_113623.jpg
 

chubs

Guru
Somehow it seems to me that if those little wires are broke, the solenoid plunger wouldn't be energized pulling the plunger in, making contact with the battery and motor contacts. If it "tries to start and the solenoid "disengages" the plunger disc should be kicked out away from the battery and motor contacts causing the motor to stop spinning. Is the plunger spring intact and working like it should? I think I'd check the other end of the starter, where all the drive parts are also, for problems.
 

Mickmorris

Well-Known Member
Supporting Member
OK, I need you to check this. There is over 50gs of vibration at the transmission on these bikes, and because when starting this terminal gets hot.
View attachment 124789
Disconnect the battery, and take the cover off the back of the solenoid .
View attachment 124790
Remove the plunger and spring. Clean the contacts while your in there.
View attachment 124791
Take a small screw driver and gently stick it between the wire at this solder joint, and see if it is broke loose. This is a common problem on the 03-04 bikes.
View attachment 124792
Wow. That’s some good info right there! Thanks for sharing this
 

Alaska Jay

New Member
The plunger, engages for a second, and starts turning the bike over then it disengag And just spins I did have to solder that wire back on. Maybe I’ll go back in there and check to make sure my soldering job is good thanks for all the info I appreciate it. I’ll let you know how it goes.
 

Mikeinjersey

Well-Known Member
The plunger, engages for a second, and starts turning the bike over then it disengag And just spins I did have to solder that wire back on. Maybe I’ll go back in there and check to make sure my soldering job is good thanks for all the info I appreciate it. I’ll let you know how it goes.
If the starter engages and remains spinning you probably have a jack shaft issue. All the solenoid does is connect the positive side + of the battery to the neg- side in order to spin the starter. Pull the starter and bench test it and if need be this is a link for the rebuild parts you may need.
https://www.bigdogpartskingpin.com/...65930&pr_ref_pid=4520468611210&pr_seq=uniform
 

HMAN

I just like my Freedom
It could be the lock tab on the end of the starter gear has broken? Had 2 of em do that so far. Not sure why they break? They are soft tho... Or the 1/4" bolt has started to loosen?
 
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