Starter/bendix wire

[Whistler]

Met a fellow Big Dog '06 Chopper rider at Bikes, Blues, and BBQ in Fayetteville, Ark. this past Sept that had a similar problem. He kept getting that "click, click, click" sound when he pushed the start button. He spent an hour or more opening the starter, cleaning the contactor, etc. to no avail. Finally, he notice the wire that provides power to the starter contactor coil was frayed and almost broken open. This connection was so bad it couldn't provide enough current to suck in the starter coil. A simple cut and reconnect with the full wire diameter fixed the problem. Hope this helps.

:2thumbs: :2thumbs: :2thumbs:

 

[Nomad2day]

Mine was completely fubar and I cut the boot out of the starter thinking I would just replace all of it.
Here is the number BDM gave me for it. I ordered it through Wicked Bastard but have not got it in yet to see if it is correct.
3ea BDM170-00145 BOOT, RUBBER 0.75ea 2.25
Neil

 

[BigDogBro1]

The insulation is also a water seal. If it's not taken care of the water will corrode the copper strand wire and seep down into the starter causing problems.

Re-cover it with heat shrink tubing and seal it to the grommet end going into the starter with black silicone or liquid tape.

3ea BDM170-00145 BOOT, RUBBER 0.75ea 2.25 - I think is just the boot end over the solenoid nut, not the wire.

The wire insulation and lower seal grommet is a molded part for the starter. The boot is just the upper cover.

 

[Nomad2day]

Thanks Bigdogbro1,
I guess I need to start looking again then. This is what I asked Dan at BDM.

Can you give me a part number for the rubber boot that goes between the
starter and solenoid seeing how I need one. I need the whole thing. Boot
in the starter housing, cable cover and boot on the solenoid.
A set of rubber gaskets for the intake manifold. 07 Bulldog EFI.I also
need the rubber intake gaskets "manifold gaskets" item #7 on the 2007
Bulldog

And the number for the Internal "C" clip that holds the throw out
bearing assembly on. It is item #11 Retaining ring keyhole fitting on
page 6-3 rev B in the 2007
Manual.Not the small one for the bearing but the aluminum carrier that
hold the bearing in place.

Kinda need this stuff to finish putting the sled back together. I could
pass the info on to dealer so he could order the stuff for me...
If you could point me to someone who could help me with these items
would be cool too...


He did reply with,

Neil, The only starter repair parts that we have is a solenoid repair
kit (BDM170-00184). This has the gasket that fits between the solenoid
and the starter. The boots that cover the cable terminals are
(BDM170-00145). The Intake manifold gaskets are (BDM100-00256) X 2). The
manifold to throttle body o-ring is (240-000276-00). The cir clip is
BDM240-00730.

Neil

The boot section in the starter housing pulls straight out and the rubber on the wire is crimped to the wire at the solenoid end.

 

[BigDogBro1]

The bad insulation part you show is a part of the starter from the starter manufacturer. Either buy a new starter or you will need to disconnect the cable from the solenoid. Slide a section of heat shrink tubing over the end of the cable as far down to the starter as possible. It should cover the upper terminal crimped area as well. You may have to use some silicone at the starter grommet end to seal the shrink tube to the grommet. Then slide over the boot cover end. Clean the starter connection stud and wire terminal end of corrosion. Make the connection and slide to boot over it and secure it around the solenoid stud base for the seal.

That's how I fixed ours dogs and Seatmakers.

As far as your other parts you need, you'll have to get back with your dealer.

 

[Nomad2day]

I cut the boot in half that is in the starter so that is not a option.
Where can I get the part I need "Bottom boot"or does it come with the cable?
Where can I order it from. I asked a while back if our starters are Spyke brand but I never got a reply to that thread.
Can you tell me where to purchase what I need?
Thanks Bro...#1
Neil

 

[BigDogBro1]

From your earlier post:

Dan (BDM)
The boots that cover the cable terminals are
(BDM170-00145).

Check a Harley Dealership. They may have a suitable replacement.

 

[Nomad2day]

I will do that BigDogBro1,
I will call the manufacture of the starter as well and see what I can do. Seems a lot of people have the same problem. Perhaps we need to get a group buy on them so everyone can stock up on them.
I will be in Ann Arbor Mich sometime here soon at the Fanuc Robotic plant for some training and I will have to give you a call and hook up and have a cold one or two......if you got time for another Bulldog rider.....

 

[BigDogBro1]

Neil,

Once you make the cable repair with heat shrink tube it shouldn't need anything more until the starter gives out.

Sounds like a plan! I always have time for bikers and beer.

Let me know ahead of time so I can make arrangements to meet with you.

Send me a PM.

I work out by the Ann Arbor Municipal Airport south side of town.

 

[Nomad2day]

Neil,

Once you make the cable repair with heat shrink tube it shouldn't need anything more until the starter gives out.

Sounds like a plan! I always have time for bikers and beer.

Let me know ahead of time so I can make arrangements to meet with you.

Send me a PM.

I work out by the Ann Arbor Municipal Airport south side of town.

Thanks will do....
I do not have the boot that goes into the starter housing seeing how I cut it out so there is just a hole there......I sent Spyke a email asking for a part number..
Neil

 

[RAW Blue Rider]

Go to the hardware and buy a roll of SPLICING TAPE, about $8.
It is rubber in a tape form.
Once you stretch and wrap it around the wire it becomes just like a solid rubber tubing.

 

[LDO]

Mine was completely fubar and I cut the boot out of the starter thinking I would just replace all of it.
Here is the number BDM gave me for it. I ordered it through Wicked Bastard but have not got it in yet to see if it is correct.
3ea BDM170-00145 BOOT, RUBBER 0.75ea 2.25
Neil

Mine looked just like the above pic. I took all the rubber pieces off, cleaned the cable and treated it with some dialectric grease, took some heat shrink, automotive grade webbing wrap and some black RTV. I got a new boot from a local shop off one of their core starters. Also squeezed some RTV inside where the boot has a gap and here was my final product.

 

[Chopper Dave]

I looked at mine and its cracked also....I just put some electrical tape on it....so....would this be considered as a warranty issue?

 

[Chopper Dave]

Thanks Alhall:up: I went to the hardware store and bought some liquid tape....took off the electrical tape and brushed the liquid tape on....going to let dry and put a few coats on!
here is the stuff that I used.....

Performix Liquid Tape Electrical Brush on Insulation

 

[Moespeeds]

I think it's a pretty common problem. The starter I just took off a friend's 2005 was totally bare, and the re manufactured starter I just received is split right out of the box. That rubber tape someone suggested is great stuff, it's what linesman use on high voltage connections on telephone polls. Never saw liquid electrical tape before, I always used RTV, I'll have to look for that stuff!

 

[PhillyBulldog]

Thx for the heads up. Just checked up and found the same problem with the wire to the starter. Scoot is a 07 Bulldog. Will call the dealer to see if covered under warranty but until then will have to shrink wrap and find that "liquid tape" stuff to seal.