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fuses, ironhead, solenoid, starter bendix

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  #1  
Old 9th April 2020
MotoSteward MotoSteward is offline
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Exclamation Starter Solenoid problem/ Blowing fuses

When I switch from high beam to low beam I blow three fuses.

This is on a 1976 XLH


I have a three post spring loaded “car style” ignition. I run 4 wires out of it. One to the relay from the battery post. One from the coil to the Ignition post, this also shares a post with my lights. And one from the starter post to the hot side of the relay.

From battery to the relay there is a 30 amp in line fuse.

From the relay to the solenoid post there is another 30 amp fuse.

There is another fuse from the ignition switch to the light circuit that has a 15 amp fuse.

When I turn flick my hi beams on— I lose all three fuses.

The switch for my lights is currently rated 14v 22 DC.

I WONDER where I should start. I’ve checked. My starter circuit is worked properly. I recently replaced the large ground cable coming from the negative post on the battery to the frame. The old one had a small tear in it but seemed to work fine. I could turn power on and work both hi beam and low beams. Even would engage the starter and solenoid.

The problem began when the starter bendix was not turning the motor. The solenoid was not moving the arm enough to push the bendix out to engage ring gear and turn motor. I took entire starter unit off the bike. Bench tested everything. Found that the solenoid components were mechanically sound. When I bench tested the solenoid with a battery it was able to pitch the bendix out fully. THIS DOES NOT HAPPEN LIKE THIS ON THE BIKE.
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  #2  
Old 9th April 2020
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Simple way. Feel around for hot wires. For shorts. I keep a fluke and check hot to ground with ohm check and battery disconnected. If meter has a beep function. Even better.

Head light and tail light connected? No? Might check rear fender wiring also.
Cuz not sure if you induced problem with your starter work or just a coincident.

Edit: My 1980 is down because of ancient insulation and stock wiring wear. Some dude on facebook is advertising 3 warehouses of ironhead stuff. I asked him for handebar switches and full on take off wiring harness. No answer yet.

My 1980 will start and run. But I finagled the wiring for it to do so. No turn signals yet or handle bar break light. The switch is fubar.
Already got replacement switch < looks like a small momentary conact button/plunger. You screw it in and out > .
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Last edited by rokytnji; 10th April 2020 at 00:04..
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  #3  
Old 10th April 2020
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Simpler way. Bigger fuse and watch what melts.
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  #4  
Old 12th April 2020
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Quote:
Originally Posted by rokytnji View Post
Simpler way. Bigger fuse and watch what melts.
lol. But this could be a good way to fry the whole wiring harness too.
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Old 10th April 2020
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Look for worn insulation where the wires enter and exit the backbone. Looks like sharp-ish edges on mine.
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Quote:
Originally Posted by MotoSteward View Post
When I switch from high beam to low beam I blow three fuses.

This is on a 1976 XLH

I WONDER where I should start.
Find out what is shorted in the HIGH BEAM circuit. Stock wiring would have a BLACK wire feeding power to the HI/LO switch - YELLOW wire out of the switch for LO BEAM - WHITE wire out of the switch for HI BEAM.

Check for cuts in the wire where it enters the headlight.


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  #7  
Old 10th April 2020
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Quote:
Originally Posted by MotoSteward View Post
When I switch from high beam to low beam I blow three fuses.

This is on a 1976 XLH


I have a three post spring loaded “car style” ignition. I run 4 wires out of it. One to the relay from the battery post. One from the coil to the Ignition post, this also shares a post with my lights. And one from the starter post to the hot side of the relay.

From battery to the relay there is a 30 amp in line fuse.

From the relay to the solenoid post there is another 30 amp fuse.

There is another fuse from the ignition switch to the light circuit that has a 15 amp fuse.

When I turn flick my hi beams on— I lose all three fuses.

The switch for my lights is currently rated 14v 22 DC.

I WONDER where I should start. I’ve checked. My starter circuit is worked properly. I recently replaced the large ground cable coming from the negative post on the battery to the frame. The old one had a small tear in it but seemed to work fine. I could turn power on and work both hi beam and low beams. Even would engage the starter and solenoid.

The problem began when the starter bendix was not turning the motor. The solenoid was not moving the arm enough to push the bendix out to engage ring gear and turn motor. I took entire starter unit off the bike. Bench tested everything. Found that the solenoid components were mechanically sound. When I bench tested the solenoid with a battery it was able to pitch the bendix out fully. THIS DOES NOT HAPPEN LIKE THIS ON THE BIKE.


Do all three fuses blow when you switch from high beam to low beam and also when switching from low beam to high beam?

Any chance you could draw a wiring diagram of how everything is wired up and post it here?

Is the "relay" you're talking about the starter relay? Or some other relay?

.
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  #8  
Old 10th April 2020
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Quote:
Originally Posted by Yellowstone Kelly View Post
Do all three fuses blow when you switch from high beam to low beam and also when switching from low beam to high beam?

Any chance you could draw a wiring diagram of how everything is wired up and post it here?

Is the "relay" you're talking about the starter relay? Or some other relay?

.
This is the starter relay. This is also not stock wiring. And yes all three fuses blow when I switch from low beam to hi beam. The issue came about when I replaced my ground wire with a brand new one. The older one was cracked on one end but still was able to run my circuits.

Is it possible, with the new ground wire, that I am pulling out more power from the battery and now I overload everything when switching from high to low?
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  #9  
Old 10th April 2020
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The standard 3 post is B battery, I ignition, L lights and standard wiring is resetting CB`s not fuses
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  #10  
Old 10th April 2020
MotoSteward MotoSteward is offline
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Quote:
Originally Posted by 72 Ironhead XLH View Post
The standard 3 post is B battery, I ignition, L lights and standard wiring is resetting CB`s not fuses
No CB’s on this rig. All in line fuses.

The three posts I have on the ignition are B, S, I
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