Electrical issue?
- Thread starter RVH
- Start date
Fibersnake
Banjo Playing PsychoBilly
RVH,
Here is a pretty good link to checking out and cleaning up the solonoid contacts that were mentioned.
http://www.bigdogbiker.com/forums/technical/2901-starter-click-click-click.html
You can get acces to the cover and contact while the starter is still on the bike. Just remember to disconnect the battery first (negative first, postive second-during reinstall positive first, negative second. Always for safety make sure the negative is first off last on).
Here is a pretty good link to checking out and cleaning up the solonoid contacts that were mentioned.
http://www.bigdogbiker.com/forums/technical/2901-starter-click-click-click.html
You can get acces to the cover and contact while the starter is still on the bike. Just remember to disconnect the battery first (negative first, postive second-during reinstall positive first, negative second. Always for safety make sure the negative is first off last on).
RVH
Active Member
Nowww you post that link!!! Jus kidd'n Fiber. Thanks. I just finished pulling the plunger & cleaning the contacts. Looked pretty darn rough but had them fairly flat & shiney with a little elbow grease & 300 grit. Just for the heck of it I put the original battery back in to try it. Same thing. Acts just like a weak battery. Cant wait to get the new battery tomorrow and try it(knocking on wood again)...One thing I did try yesterday that I didn't mention was to manually push the compression releases. They do push down but come right back up as I release them. Is this normal? Even held them down while the girlfriend hit the starter but still sounded the same. Read somewhere on here that you can hear the releases click when you hit the run button. Is this correct? If so, how can I check them. I've never noticed them click before when she was cranking fine. Thanks again to everyone.
Throttle Jockey
Don't Look at my Member!
The compression releases kick in right when you hit the start button. Probably why you haven't noticed hearing em. When manually pushed the compression releases stay open for a bit allowing you time to crank the engine. Thats the way I understand it anyway.
It sure sounds like a battery and I hope your starter is ok.
Throttle Jockey
It sure sounds like a battery and I hope your starter is ok.
Throttle Jockey
RVH
Active Member
Anyone wanna buy a slightly used battery? Very slightly. About 2ea - 3 second burst............OK, jus try'n to be funny & keep a good attitude about this. New battery has over 15 volts by my meter. Installed it and same chit, complete with smoke. Definately coming from the starter. Do I just suck it up and order a new starter? Seen the 2.0KW on ebay for $219. What else can I check?
Throttle Jockey
Don't Look at my Member!
N8KAM
Well-Known Member
Now i know you have already replaced the battery and still have an issue.... But i just want to advise that you not second guess the battery and try to reuse the old one.... It is possible that trying to start the bike several times with a shot battery is what caused the starter to fail.. REGUARDLESS of what the volt meter and Auto Zone's load test said that old battery is most likely junk. I had the same no start issue where it felt like not enough juice and was fine after a charge + riding but after sitting over night -- no-start. load test showed a good battery...NOT. it wont even start my Honda.. Just Keep the new battery... The HD AGM batteries i have been told are made buy yous and i think BDM is switching to interstate.. my .02
Last edited:
Fibersnake
Banjo Playing PsychoBilly
Well the next thing would be to take the starter off, pull it appart and inspect. Get some good electrical cleaner and clean all the armiture and brushes. Also check the seals to make sure that you do not have primary fluid getting into it (was one of the 05 issues, not heard too much on 06 though).
Is it still under warranty by chance. If so, hate to say it (for you know it will be a hassle) but see if they can get to it quick. If not, then pull the starter and see if you can figure out what the hell is going on.
You know you may also want to check the drive section inside the primary and make sure it isd not binding or damaged on the ring or gear.
Last, if still un-sure and before what IMHO is way too dam much money for a starter (part of the nature of the beast for MC in general), maybe see if there is an old time alternator/starter shop near-by and see if they will take a look for a few bucks. Maybe something simple that they could fix and though it has been awhile, they used to be a great way to save some money and get things right.
Good luck and keep us informed.
Is it still under warranty by chance. If so, hate to say it (for you know it will be a hassle) but see if they can get to it quick. If not, then pull the starter and see if you can figure out what the hell is going on.
You know you may also want to check the drive section inside the primary and make sure it isd not binding or damaged on the ring or gear.
Last, if still un-sure and before what IMHO is way too dam much money for a starter (part of the nature of the beast for MC in general), maybe see if there is an old time alternator/starter shop near-by and see if they will take a look for a few bucks. Maybe something simple that they could fix and though it has been awhile, they used to be a great way to save some money and get things right.
Good luck and keep us informed.
Last edited:
RVH
Active Member
Thanks again guys. N8KAM, gonna keep the battery. I was just trying to make light of a chitty situation. Figures when I let a friend take my Indian to ride at the beach, the dog would get stuck on the porch. If he weren't such a good friend.................. nah, I wouldn't do that. lol. Guess I'll pull the starter this afternoon. Will it help if I down a few Crown & 7s before I start? 
Fibersnake
Banjo Playing PsychoBilly
"Will it help if I down a few Crown & 7s before I start?"
No but I would recommend good Irish Whiskey after you are done. If you are going to indulge while working on it, recommend Everclear or Don Rico 151 for beside killing the pain, it makes good cleaning fluid!!
Hang in there, you will get it fixed and be on the road again soon.
No but I would recommend good Irish Whiskey after you are done. If you are going to indulge while working on it, recommend Everclear or Don Rico 151 for beside killing the pain, it makes good cleaning fluid!!
Hang in there, you will get it fixed and be on the road again soon.
Fibersnake
Banjo Playing PsychoBilly
RVH,
From the BDM Service Manual:
Replacing Starter
ALWAYS DISCONNECT THE BATTERY CABLES BEFORE CHANGING THE
STARTER.
To remove the starter you do not have to remove the outer primary cover on the 2005 models to gain access to the starter.
Starter removal steps
1. Disconnect battery
2. Remove muffler
3. Remove pulley cover
4, Remove starter positive cable
5. Remove the starter positive cable that routes from the starter solenoid tothe starter motor (the wire harness routes through this cable).
6. Remove two (2) 3/8" - 16 x 1 1/4 socket cap Allen bolts from starter
When re-installing the starter note the following torque specifications.
Positive cable starter/terminal nut------------65-inch pounds
Starter to inner primary case Allen bolts----- 18 foot-pounds
IMPORTANT: When replacing a starter, and attaching the battery cable to the starter, it is important to NOT, over torque the positive terminal on the starter. This can cause the stud to turn inside the starter case with a significant loss of contact area inside the starter which will result in loss of cranking power or an internal short.
From the BDM Service Manual:
Replacing Starter
ALWAYS DISCONNECT THE BATTERY CABLES BEFORE CHANGING THE
STARTER.
To remove the starter you do not have to remove the outer primary cover on the 2005 models to gain access to the starter.
Starter removal steps
1. Disconnect battery
2. Remove muffler
3. Remove pulley cover
4, Remove starter positive cable
5. Remove the starter positive cable that routes from the starter solenoid tothe starter motor (the wire harness routes through this cable).
6. Remove two (2) 3/8" - 16 x 1 1/4 socket cap Allen bolts from starter
When re-installing the starter note the following torque specifications.
Positive cable starter/terminal nut------------65-inch pounds
Starter to inner primary case Allen bolts----- 18 foot-pounds
IMPORTANT: When replacing a starter, and attaching the battery cable to the starter, it is important to NOT, over torque the positive terminal on the starter. This can cause the stud to turn inside the starter case with a significant loss of contact area inside the starter which will result in loss of cranking power or an internal short.
RVH
Active Member
OK, OK I know. Why dont I buy a dam service manual. Really hadn't planned on keeping this mastiff long enough for it to break but hey, here I am....... Pulled the rear pipe then removed the screws from the pulley cover. Seen that I'm gonna have to pull the front pipe as well. Question is, does the clutch rod need to come out with the cover or should it stay in the motor? Dont wanna be putting the clutch assembly back together because some dumba$$(me) pulled the clutch rod out..... and I'll buy the manual when I get my K-9. Thanks.
RVH
Active Member
Thanks chacha but too late. I couldn't get it to seperate so I just pulled it out and left it with the cover. What kinda problem will I have when I go to put it back?.... Starter looked pretty oily and smelled very burnt. Could tell it has gotten very hot at some point cause it was a bugger to get apart. Guess I'll run it to a local alternator shop tomorrow and see what they say.
RVH --no problems. Is your rod in one or two parts? Rod(s) in first then the cover. May as well grease the rod since its out already.:up:
Your starter guy should be able to hook you up well. At a minimum clean up the contacts and any oil that may have reached the windings.
Your starter guy should be able to hook you up well. At a minimum clean up the contacts and any oil that may have reached the windings.
Fibersnake
Banjo Playing PsychoBilly
RVH,
Sounding good and if it smells burnt and oil, good chance that it has gotten some oil crossed over from the primary side at one time or another. More than a couple of the 05 had issues like that (including mine), but you may have a 06 that got some of the questionable starters.
If could also just be a bad seal. Either way, if the starter guy is able to get it taken care of for you and it works okay. May want to sit some money aside in case you do have one of the starter that had the bad seal areas.
Good luck and hopefully it will all come together here for you in the next day to allow you some time to still get over to Myrtle. If you do, try to find the BDM Truck and see what they have to say about the starter, they may even be able to get you helped out better for the long run.
Oh Chacha nailed it about the way to put the clutch rod back in!!! :lol:
Sounding good and if it smells burnt and oil, good chance that it has gotten some oil crossed over from the primary side at one time or another. More than a couple of the 05 had issues like that (including mine), but you may have a 06 that got some of the questionable starters.
If could also just be a bad seal. Either way, if the starter guy is able to get it taken care of for you and it works okay. May want to sit some money aside in case you do have one of the starter that had the bad seal areas.
Good luck and hopefully it will all come together here for you in the next day to allow you some time to still get over to Myrtle. If you do, try to find the BDM Truck and see what they have to say about the starter, they may even be able to get you helped out better for the long run.
Oh Chacha nailed it about the way to put the clutch rod back in!!! :lol:
RVH
Active Member
Thanks gents & yes, I'm up at 4:00 AM think'n about what I could do to get this going sooner. Went ahead and ordered the 2.0kw from the guy on ebay. Supposed to be here in 2-3 days.....Gas, wish I'd thought about the tape. Not so much for the frame but I did put a small scratch on top of my primary cover when I let the starter gear touch it. Had micro-fiber towels all over the area trying to protect it but chit happens. I didn't cry but I did pop a top after that, lol.
Yeah the painters tape is a must if you plan on doing any amount of wrenching. In those high impact areas or areas where you know you'll be busting a wrench against... I have been known to use like 8 layers.
At one point my bike looked like it was blue and not black!
At one point my bike looked like it was blue and not black!