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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #11  
Old 2nd March 2013
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rivethog rivethog is offline
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Quote:
Originally Posted by IronMick View Post
Of course, this will not work in a case where we want to check for spark. I wonder what other guys here do in that case?
2 of these work quite nicely:

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  #12  
Old 30th March 2014
curkel207 curkel207 is offline
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Shooter like this


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  #13  
Old 30th March 2014
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I keep alligator clip wires in different lengths in my electrical drawer, and use them to ground the plugs. You can get different size clips, like the one above, or use the small ones, and clip them to the ground strap above the electrode. Years ago, I used a long piece of wire, stripped down about one inch, and put it in the plug wire, and installed the plug, then do the same to the other end, and wrap around a good ground, or battery ground. Not to mention, you will come up with a million things to use them for. You can buy the round extendable test wires, that pull back into a container, if you just have to have the best.
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  #14  
Old 5th June 2020
LetsDoIt LetsDoIt is offline
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Default going through tests

Quote:
Originally Posted by IronMick View Post
Here we are using the same technique as in the Voltage Drop Testing Sticky note.
  1. Do the battery load test and generator amps test from the Charging System Checkout Sticky note before proceeding
  2. Begin with the ignition key off
  3. Test for 12 volts at the long stud of the solenoid
  4. Disconnect the spark plugs to prevent the engine from starting. If the bike has any electronic ignition insert any spark plugs into the wires and ground the plugs by setting them onto the cylinder head fins
    EDIT: Check out post #s 7 to 11 of this thread before doing the above step
  5. Momentarily run a heavy gauge cable directly from the battery +ve terminal to the starter motor terminal [or directly from the solenoid long stud to the solenoid short stud]; the starter motor should activate [but it should not turn the engine]; if it does not activate then the starter motor needs to be serviced
  6. Disconnect the green wire from the solenoid terminal to prevent it from activating
  7. Turn the ignition key on to the first key click
The gray wire from the IGN circuit breaker brings 12 volts to the STOP switch, and from there a very short white wire goes to the start button. When the button is pushed a black wire brings the 12 volts from the button to the start relay.
  1. Test both sides of the IGN cb
  2. Press the start button - you should hear a quiet click at the start relay; you should be able to feel the click with a finger on the body of the relay while you press the button
  3. Press and hold the start button while testing the black wire at the start relay. If you did not sense the click or if this test shows a significant voltage drop carefully dismantle the handlebar switch housing and test at both sides of the STOP switch and both sides of the START button
With the start button pressed test the free end of the green wire that is disconnected from the solenoid. If there is a significant voltage drop then there is a problem with the start relay.
  1. Release the start button
  2. Turn off the ignition key
  3. Re-connect the green wire to the solenoid
  4. Disconnect the cable at the starter motor
  5. Turn the ignition key on to the first key click
Press the start button. You should hear a loud click from the solenoid. With the start button pressed test for voltage at the free end of the cable that you disconnected from the starter motor. If you did not hear the loud click or if there is a significant voltage drop there is a problem with the solenoid
  1. Turn the ignition key off
  2. Re-connect the cable to the starter motor
  3. Turn the ignition key on to the first key click
  4. Press the start button
The starter motor should turn and crank the engine. If not then there is a problem with the Starter Drive Gear Unit [AKA the bendix, the starter clutch, or the starter pinion gear] and associated parts in the Starter Shaft Housing.

so I got a battery hooked up and going along these steps testing everything, if a test fails you can not go on to the next one correct ? the one test that was not going well was the "green wire" to solenoid, the voltage is lower, also the I did not hear a "click" from the relay and both sides of the start and on off in the handles tested correctly, does this mean I cannot go on to test the solenoid ? what should I do now,

Last edited by LetsDoIt; 5th June 2020 at 22:20.. Reason: add
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  #15  
Old 6th June 2020
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Quote:
Originally Posted by LetsDoIt View Post
so I got a battery hooked up and going along these steps testing everything, if a test fails you can not go on to the next one correct ? the one test that was not going well was the "green wire" to solenoid, the voltage is lower, also the I did not hear a "click" from the relay and both sides of the start and on off in the handles tested correctly, does this mean I cannot go on to test the solenoid ? what should I do now,
Replace your starter relay.
If with the new relay, your “green wire voltage drop test” and the “relay click test” pass, test if you can start your bike? If you can’t, move on to solenoid test.

Last edited by billeuze; 6th June 2020 at 15:47.. Reason: Punctuation
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  #16  
Old 6th June 2020
LetsDoIt LetsDoIt is offline
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what actually happened was the starter relay was not grounded correctly, now it is connected to the case grounding in the same spot as battery and is working well
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  #17  
Old 6th June 2020
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Glad you got this sorted out
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