Starter/Solenoid ???

[Bulldog02]

Hello everyone!

Ok...I have been searching the threads and still doing it but here is the problem. FYI...Bike will start when push started.

Battery fully charged hit the start button and hear a click but nothing.

As per one of the threads I disconnected the GREEN wire and put a volt meter on it and when I hit the button I get the 12v.

So I then pulled the solenoid cap off and pulled the plunger out, used 150 grit paper and cleaned all contacts and also the plunger, not really bad at all considering some of the pics I've seen posted. Put it back together and same click. Removed the cap again and as per another thread pushed in the plunger with the handle part of the screwdriver and hit the switch and while I was applying pressure I could feel the plunger moving slightly back and fourth but would not turn over. So I guess my question is what now??
Thanks,
Tony
:flag:

 

[woodbutcher]

big inch motors need more like 12.8v minimum. could be a bad cell, have a load test done. do you have compression releases on the '02? they were not standard and the heads may not even be drilled for them, if they are drilled, highly recommend putting them in. if you don't, everything needs to be in top condition or you are looking at a continuing problem.

 

[Bulldog02]

The solenoid wire was reading around 12.75 during the test with the battery fully charged. I will load test the battery tomorrow. As far as I know there are no compression releases. I havent had a problem till recently. Thanks for the input woodbutcher!

 

[totall2tall]

bypass the solenoid and put the booster box on the starter itself and see if it throws that way. then you will know it its the starter or solenoid. then trouble shoot the solenoid. Mine would not throw unless it had good voltage to so make sure your booster box is fully charged.

 

[FrankBDPS]

There should be a ground strap running from one of the starter bolts to the frame. Check the connections on it.

 

[Bulldog02]

Had battery load tested

Voltage: 12.83
Measured: 503 CCA

Double checked all connections, all good. I will try bypassing the solenoid and go from there. Please correct me if I'm wrong, if I can push start it and I dont hear anything grinding like a starter gear is it most likely the solenoid? I understand once I bypass it and it turns over its not the starter.

 

[francoblay1]

http://www.bigdogbiker.com/forums/how/26704-what-do-if-starter-wont-turn.html

http://www.bigdogbiker.com/forums/how/10327-how-clean-solenoid-contacts-starter.html

HOW TO....

 

[SCOTTx88]

Get a slam button too, save on the push starting.

 

[boomer4444]

really check your ground to your frame from the battery,my bolt had bottomed out and wouldnt give a good enough ground to turn starter,

 

[Bulldog02]

Thanks for all the input.

Francoblay1, yes sir I have used those links to do some of the testing. I havent had a chance to get a 4g wire to do the bypass test.

SCOTTx88: Yes I ordered a slam button the other day.

boomer4444: The ground from the battery to the frame appears fine but I will check all again.

Thanks for all the help and support. I will update in a couple days.
Tony

 

[francoblay1]

You almost there, make sure you keep us posted. :up:

 

[Bulldog02]

Ok, sorry for the delay. I ordered All Balls Cables and replaced all three of them. I did notice where the ground cable attaches on the bike was full of the paint from the factory. So I scrapped it off to raw metal and put dielectric grease on all connections. Hooked everything up and did get the starter to turn slowly but didn't sound good, grinding sound. So must be the starter. Everyone says its not hard to remove, I will look for the thread and go from there. Thanks again!!!

 

[Mr. Wright]

Get ahold of the Kaptin, he'll rebuild it better than new.
Wild Steed Worx & Services, When the road is your trail

 

[Bulldog02]

UPDATE!! Got the dog barking again. Yeah, the starter was shot. Took it out and down to the starter repair shop, they took it a part and the bearings were done along with the bushings, four hours after I dropped it off and $141 later running like a champ! Thanks for all the support and advice.

 

[liferider]

Seriously my 03 chopper did not have compression releases and I ate like 6 starters in 4-5 yrs! Then I joined the site and was told about putting in compression releases. Have not messed a starter up again. Get a small mirror. Go to the top of your S&S rocker box in the middle is a open area. Turn the mirror at an angle so you can look down the hole and see the top of your head through the rocker box. If you see what appears to be a plug or 3/4" nut your heads are pre tapped at S&S for compression releases. There easy to install and wire in to your starter relay. Whenever you push in the starter button the relay sends current to the starter and the releases. You can find them in J&P cycles as well as members on here sell them. If your head does not tapped then I highly recommend next winter pulling both and having them drilled and tapped. It's not hard to do. When I sent my heads on my HD Ultra Classic to Kendall Johnson to port polish & deck them .010, my compression was going to be over 10/1 when we finished so he also tapped my heads for releases. And at 11/1 compression now on the HD ,I'm glad I did it! Cost should be ball park $100.00 a head to drill &staple. Off my head I think the electrical release with relay wiring kit is $300.00 -$350.00 neighborhood. Ok looked them up for you. Drag Specialty has S&S electrical compression release kit

 

[Bulldog02]

Thanks liferider!! Yes they are tapped and that will be a purchase once the summer is over...well here in San Antonio its almost never over. Dropping money on my boat now.