At wits end hard start

H

H3is3m2n

Member
05 Chopper DT
117cu
New Bandit clutch 500 miles on it
new starter from BDM
New Braille battery
590 cam

I am really frustrated, I have 11k on the bike and it is hard starting again now after a new battery and starter. The old starter was beat up and the bike would not start. I have combed through every thread about this. I have the compression releases direct wired to the starter.

Bike has been starting fine - yes the battery is on a tender. I rode 30 minutes, stopped to get gas and it would not start. Heard a clunk, then click click. I put bike in gear, rocked it back and forth and tried again. Nothing. The sound originally sounded like there was a bad tooth on the gears. All gear teeth are in good shape...

Pushed the bike away from the gas pumps and checked all connections. waited a minute and the bike struggled to try and crank. I shut it off and manually pushed down compression releases, burnt fingers and the bike turned over slowly but started.

I rode down the street and stopped at a restaurant. The bike was slow to start but it did start again. I rode home over 30 minutes and hooked up a tender - thinking the battery needed charging. The low voltage trickle charger only charged for 2 minutes before the battery was fully charged.

I have ordered new positive and negative cables but the old ones are in good shape. I do have accent led's direct connected to the battery but they have always been like that probably 5000 miles, they are switchable on/off.

My questions:
Could I have the primary drive chain too tight? I checked tension when cold and it is in specs.

Could I have a sticking compression release? They are definitely opening and closing. It seems like the bike starts better when I manually depress the rear, not always the case.

After sitting the bike starts easily. I just started it 3 times in a row and the battery is still fully charged.

Could I have a bad new starter? Although the bike is acting the same as when the old battery and starter acted.

Could the clutch be too tight? The bike is shifting fine. There are no issues once started. Just really hard to start sometimes. All EHC lights are lighting as they should.

Any thoughts/comments are greatly appreciated.
 
Little-Boo

Little-Boo

Well-Known Member
Troop Supporter
Have you checked your stator / Charging system. Maybe your bike is running on Battery only and when it get down or discharged it makes it hard to start till it sits for while and starts again. Sound like you have done about all one can do to keep it going except for the charging system :2thumbs:

Carlos :whoop:
 
H

H3is3m2n

Member
Checked the battery after running hours, it trickle charges for maybe 5 minutes. I will run it with the battery disconnected tonight. Thanks
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Just hook up a meter on the battery when the bike is on should be 14.4 volts if charging system is working properly.

I would focus on the grounds as well.
 
H

H3is3m2n

Member
I started it 4 times this morning cold. New cables should be here today. This is definitely an issue when hot. I am taking off the LED's today too. I am going to check the slack in the primary chain today as well.

I have 2 bike rally's starting next weekend, I hope I can figure this out....
 
H

H3is3m2n

Member
14.9 VOLTS BEFORE START, 14.50 running. Dips down to 12 or 10 when starting, with a slight hesitation occaisionally
 
KaptinAmerika

KaptinAmerika

Guru
Remove the solenoid cover.
Make sure the bike is in neutral.
Using the handle side of a screwdriver push in firmly on the solenoid plunger to engage the starter.

Choking and not turrning over?
Pull the starter and bench test it.
Spins right up no problem?
a) You have a main starter circuit issue
Not spinning up
a) You have a defective starter

Spins up no problem?
a) You have a secondary starter circuit issue
i) Check the starter button in your hand controls
 
H

H3is3m2n

Member
took bike around block, just duplicated starting issue when hot and now I have a fault light and run button not lighting on EHC. The fault light for Air ride mode constantly lit, I don't have air ride. it goes out when I hit run or start but neither light on the EHC lights up for those 2 items. Side note, brake lights work, turn signals, horn all good. This is a hot only issue, started fine 12 times when it was cold. No other fault lights are lit except that one.

Thanks for all the help
 
V

V

Guru
It seems like the rear compression release is the first one to wear down. I had the rear one start hanging up at just over 5000 miles and had to replace it.
 
H

H3is3m2n

Member
both compression releases are functioning but do thye get clogged? I charged the battery and the bike started right up this morning....

New cables will be here this morning, see what that does.

Thanks everyone
 
H

H3is3m2n

Member
this is an 05 with EHC, If I am correct, there are no relays unfortunately. I will post if the cables solve the problem. Sending old starter out to WIld Steed Worx today
 
Little-Boo

Little-Boo

Well-Known Member
Troop Supporter
Yea, fixed now will you let please let us all know what the fix was so that in the future we may be able to help some else with the same problem. :flag:

Thanks

Carlos :2thumbs:
 
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