Starter/Solenoid Issues

[dagjr]

2003 chopper 107s&s

I noticed the wiring between the solenoid and the starter needed tightning as well as shrink wrapping. Pulled the starter off, opened the solenoid and noticed the wire to the brush that connected the solenoid to the starter needed to be resoldered.

put everything back together and the bike clicks one time at start up. Have no nuetral light and the horn barely makes a peep. (no problems prior to work)

bike will start if I have someone push the plunger in while hitting the run button.

any ideas? waiting for the service manual to be delivered.

the odometer has been fading in and out for a couple of months- EHC problem?

 

[GDOG_PITBULL]

Sounds like a battery issue first off, then clean the solenoid contacts. Had the same issue.
G

 

[dagjr]

bought a new interstate battery prior to staring it by pushing the plunger

 

[dagjr]

will try cleaning contacts though.....thanks

 

[dagjr]

cleaned contacts still no good. traced 2 wires to my transmission from the harness. There are two post that tie into a large nut. I assume this is the transmission sensor.

the two post rotate 1/4 turn both clockwise and couter clock wise in this nut. should they be able to do this?

somwhere along the way I lost my neutral light

 

[Eric]

cleaned contacts still no good. traced 2 wires to my transmission from the harness. There are two post that tie into a large nut. I assume this is the transmission sensor.

the two post rotate 1/4 turn both clockwise and couter clock wise in this nut. should they be able to do this?

somwhere along the way I lost my neutral light

those 2 post are on the nuteral safety switch,,, thay should be snug.. not lose.. that wont affect the starter.

 

[mobsta]

I seem to recall someone saying interstate batteries didnt have enough cca's or something like that.03's dont have compression release's or do you?I wouldnt point at the ehc.the other question I have is did this problem start after your wire repair or before the repair?If after I would trace my steps.I would have to agree with GDOG at this point.Battery!But again what the hell do I know?hope you get it fixed

 

[dagjr]

problem started after wire repair. no compression release. bought a new battery for the heck of it.

new battery which is supposed to be plug and play with 330cca. put it on a tender over night. will try again tonight.

dont seem to have enough juice to magnatize the solenoid.

does anyone know what is required for cca?

 

[Analog]

problem started after wire repair. no compression release. bought a new battery for the heck of it.

new battery which is supposed to be plug and play with 330cca. put it on a tender over night. will try again tonight.

dont seem to have enough juice to magnatize the solenoid.

does anyone know what is required for cca?

Not sure about your 03, I have an 08 K-9, had a small glich when I went to start my bike, thought it may have been the tender, went to battery one with tender and bike, anyway they checked my battery and it had 535 cca's at 13.45 volts. They said they would even have a battery to match that kind of cranking amps for a bike. They couldn't belive a battery that size with that much cranking capacity. I don't know who is making Big Dogs battery's but I would suggest staying with the Big Dog Battery if you replace it. Hope this helps.

 

[dagjr]

thanks bud, took a brake from it yesterday. the service manual should arrive today.

will have the battery tested as well. the old battery was handling the job and was a HD.

when the problem started t crosssed referenced it to the interstate.

the module that sits on the battery has a yellow LED that indicates it is an ignition issue.

the red indicates a starting issue.....

the yellow one is the one that comes on....who knows?

 

[dagjr]

I have been waiting for days for the service manual to get here......arrived today!!!

they left out the wiring schematics for 2003 yes my year.........i am pissed!!!

would anyone happen to have pages 23-28?

 

[dagjr]

type of solenoid - starter issue

I think I may have found the problem with my bike in the service manual.

see the attachment in case someone has a similar issue. I may have wasted a 100 bucks on a new battery.

I will know tomorrow when I work on it if this is the fix.

 

[Analog]

I think I may have found the problem with my bike in the service manual.

see the attachment in case someone has a similar issue. I may have wasted a 100 bucks on a new battery.

I will know tomorrow when I work on it if this is the fix.

Hey thanks for the post, will make copy and place in my manual!
Good luck with your bike!:2thumbs:

 

[dagjr]

FIXED! Starter/Solenoid

finally got it fixed. see attached picture, had a broken wire to the neutral sensor which wasnt completing the circuit.

Acording to the service manual the module was shutting down due to open circuit.

I also backed the nut off per the service manual. cleaned the contacts yet again.

 

[jbdubs080D]

Did you hear a whinding sounds when the starter button was pressed. As is the wheel was spinning but just not making contact, or did you have no movement of the starter when enaged. - I'm getting both - Any Ideas?

 

[francoblay1]

finally got it fixed. see attached picture, had a broken wire to the neutral sensor which wasnt completing the circuit.

Acording to the service manual the module was shutting down due to open circuit.

I also backed the nut off per the service manual. cleaned the contacts yet again.

 

[Mr. Wright]

Your loosing touch Franco. New guy that hasn't done an intro, drags up an old thread, and you just added to it.
Drinking early tonight?