The starter on my Big Dog won't engage

[BDCU]

Hey Guys, I just joined the forum and I need some help.


I recently purchased a Dog, a 2007 Mastiff and apparently inherited someone else electrical/mechanical problems. I’ve followed a couple of other postings on here of similar topics, but none have exactly the same symptoms, so before I shell out a few hundred dollars for a new starter I want to make sure I’ve eliminated any other possibilities.


When I try to start it, all I get is a single click sound, which I believe is the solenoid. Here is what I’ve done so far:

1. The battery is brand new and fully charged
2. I’ve taken the starter out and, while the pinion gear doesn’t turn extremely easy because of the pressure from the brushes, it easily protracts and retracts, bearings spin freely, and overall, isn’t very dirty and has no seized parts, but I still cleaned it
3. All the connections to the battery, solenoid and starter have been cleaned with emery cloth and tightened securely
4. I’ve taken the steps outlined by DRBarnhart for testing the solenoid which seems to be working fine
5. All the lights, including the speedo operate
6. The volt reading on the battery is 12.7, and during the time when I press the start button, drops to 11.8 v at the solenoid which is acceptable

So I’ve come to the conclusion that, even though the starter looks good, it must be faulty since it doesn’t turn/engage. Does this seem like the right conclusion?


Thanks, your input will be greatly appreciated!

 

[Tei]

I never had this issue on a bike but on a car. What you described was a defective solenoid for me.

 

[Brew]

Welcome from Washington State, hope you enjoy the site. What kind of new battery are you running? If it's new did you charge it up for at least 12 hours prior to using it? It's best to put a new battery on a charger over night before using. Just saying and also take the battery to your auto parts store and have it load tested to be sure it's truly good and doesn't have a dropped cell...

 

[BWG56]

Your Introduction
Usually your first post is an intro, might get a better response

 

[BadDawg Bill]

Take the starter down to your local starter/alt repair place and have them cut the armature, replace the bushings and test the solenoid. It's cheap and quick. Welcome.

 

[BDCU]

I apologize for the directness in my first post, but for those of you who've had a machine that won't work an you can't figure out why, then you know how frustrating and anxious you are to find a solution so you can get back to riding.

I've been riding for over 20 years, foreign bikes generally, but have always liked the the choppers, especially Big Dogs. The fact that they're not like every other bike on the road is probably one of the main reasons that I'm attracted to them.

Thanks for the advice BadDawg and Brew.

The battery had been charged overnight and SHOULD be fully charged, but I haven't had it load tested.

As far as the starter...anything that is relatively inexpensive in identifying the problem is a step in he right direction, cause the option to drop hundreds of dollars is always available, just not the first choice!

Thanks again guys.

 

[BDCU]

And the battery I bought for it was the Duracell Ultra 20HL.

 

[chubs]

Did you remove the end plate from the solenoid and check for burnt contacts? (the 2 heavy copper posts, and the copper "washer" ) Be careful if you don't disconnect the battery, it's easy to bump things and get a pretty good arc!

 

[TapioK]

As chubs hinted, remove the wires from battery before taking solenoid apart! Or you most likely melt the bloody spring while removing it!


Tapio

 

[BDCU]

Ha, yes, I've learned the hard way years ago working on my car to always disconnect the battery first before working on anything associated with the electrical system. However, I still occasionally change a home outlet or switch without shutting off the power, go figure.

When I took the solenoid apart (somewhere around step 2 above), all the contacts were in fine shape. I really believe the starter is the culprit here and will just have to get it checked. I'm preparing myself to spend $$$.

 

[FrankBDPS]

Have you tried to run the starter while it is lying on the bench? Another words take a set of jumper cables and hook it up to a battery and see if it spins. Like Bill said the armature,brushes and armature shaft bushings need to be in good condition also. A lot of us have sent our starters to Curtis at Wildsteedworx. He is a vendor on this forum and does excellent work. Good luck.

 

[BDCU]

I did try that Frank and nothing happened which also was an indicator that the starter was gone and the repair shop confirmed it, so now it's in the process of being rebuilt. Wish I had know that there was someone like Curtis who I could have sent it to, but I'm the kind of guy who typically will analyze. research and move forward with a decision in short order. In the future, I will ask my friends here on Big Dog Biker about contacts they recommend, because I'm pretty sure that this won't be the last time I'll need your help with some sort of problem.

Thanks again everyone for your suggestions. I'll let you know how everything turns out.

 

[BDCU]

Guys, on a side note, just got off the phone with Curtis from Wild Steed Worx about some plugs for the holes where the sissy bar attaches...hell of a nice guy! Just goes to show you what I've been saying for years that the best people I've come across have been bikers and campers!

 

[BBChopper]