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  #11  
Old 17th October 2021
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Spending money to replace (even working) old maintenance items is good preventative medicine. When issues arise, it's better to be thorough in checking & replacing associated items to keep that area of the bike (whatever it is) up to snuff to prevent roadside issues.

Relay - Good Call - Minimal cost - But do check your cables as well.

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  #12  
Old 17th October 2021
Andy56 Andy56 is offline
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Quote:
Just a simple electromagnet that creates a secondary contact.
I think they have been that way forever.

I did wonder about seeing if there was a solid state device for the 2008 I have here as the system relay has failed a coupl of times.
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  #13  
Old 17th October 2021
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Holy crap! For $6.38 I seem to have solved everything, except world peace. Starter turns over instantly, no sign of having to "wake up" the battery at all. Since I'm the only kid on my block with a lithium battery, I just thought from reading about them it was normal for them to be a bit sluggish on first attempt. Looks like the starter relay was the cause of that issue too, as well as the lack of response to the starter button. A very happy camper!

John
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  #14  
Old 17th October 2021
Tomcatt Tomcatt is offline
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Quote:
Originally Posted by John Harper View Post
It usually does a half ass turn over first push, then the next time turns over strongly. I use the Shorai maintainer after each ride, and it seems to function normally.

Resting Voltage, just checked. 13.49V So, battery appears good. Should I put on the BMS and see if it gets any higher?
13.49V is plenty, and I assume recently taken off the charger. Mine, after sitting 24 hrs off the charger showed 13.24V. It was 13.89V right off the charger, 13.54V half an hour later. That's on a '17 1200 with its' industry leading drain on the battery because the ignition switch doesn't really turn everything off and with my GPS connected, but turned off. It also isn't really off if it's connected electrically as it sees the bike's system as a voltage source to keep its' battery charged.

Quote:
Originally Posted by John Harper View Post
Maybe this blind squirrel found a nut!

Swapped out the relay and hit starter button, instant turnover, no hesitation. We'll see tomorrow when I fire it up in the morning. On the maintainer for BMS cycle.

Hopefully my suspicions were correct. Who knows how long I've been dealing with a sluggish relay and maybe blamed it on the lithium battery?
Sounds like it's now starting like it should. I know mine NEVER spun on the starter with a lead acid battery the way it does with the LiFe battery.
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  #15  
Old 25th October 2021
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It's wise to perform preventive maintenance on these Denso OSGR starters and they're very easy to work on. Contacts are the major reason for starter replacements by shops but owners can do the labor at no cost.

I remove the solenoid end cover on any new to me HD and inspect the contacts. Since a complete kit is around 20 bucks it's painless.

The kits with all the seals like

https://www.amazon.com/Harley-Davids...Y%2CB00TFCEFLY

are best. I've used several of the above but OSGRS are common as dirt on cars and trucks so kits are plentiful from various makers. If in a hurry your local starter rebuilder should have them in stock.

I usually replace them if I can remove the old ones without pulling the primary cover since I'd rather not buy a gasket/seal kit. If the nut n the bottom stud isn't frozen you can usually get it off though you may have to grind a wrench to fit. Do NOT try to free a stuck nut by hitting a screwdriver or chisel as the solenoid is easy to break!

I replace contacts any time I remove a primary cover if they show significant wear since the starter bolts are only accessible with it off (I may install threaded inserts and different bolts next starter pull I do since there is no particular reason a starter should not be bolted from the outside).

All my HDs with Denso starters get the pushbutton solenoid end cover as backup and for bumping the engine during maintenance.
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  #16  
Old 25th October 2021
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Thanks for sharing that. I too have the push button end caps and have also wondered about changing the bolt up situation to not have to pull the primary cover to service the starter.
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  #17  
Old 26th October 2021
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Great input, everyone. Since my bike is an early 1991, and came as an 883, but now a 1250, I am a bit concerned about how the 883 starter will fare with the increased power. My FPM shows different starters for 883 and 1200 models back then, not sure if that's still true today. Time will tell, so far, seems to start up just fine in regards to relay and solenoid/starter motor. But, I will be vigilant.

From my FPM, however, it looks like the "push button" accessory on the solenoid may not be doable on this 883 starter. The FPM just shows the entire assembly, with no parts breakout. Interesting. But the 1200 starter in my FPM does show the solenoid components broken out.

Agree with having reinforced threaded inserts in the case so bolt in starter from the outside. Most automobiles seem to be able to do it that way, don't they? At least the several starters I've changed out over the years.

John
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  #18  
Old 26th October 2021
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I was pushing the start button 4 or 5 times to get it to kick over, and I figured it was either the push switch or the relay, I turned off the radio in the garage and listened as I pushed the switch. I heard a click and no starter motor. I verified it a couple times, then I took off the starter relay, removed the cover and ran some 400 sandpaper thru the contacts. Got a lot of carbon and crap off the contacts, after that the starter caught on first time every time, Its just a $10 relay but its easier to clean the contacts then to drive down to O'Riley to buy another relay.
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  #19  
Old 26th October 2021
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Quote:
Originally Posted by andy2175m4 View Post
I was pushing the start button 4 or 5 times to get it to kick over, and I figured it was either the push switch or the relay, I turned off the radio in the garage and listened as I pushed the switch. I heard a click and no starter motor. I verified it a couple times, then I took off the starter relay, removed the cover and ran some 400 sandpaper thru the contacts. Got a lot of carbon and crap off the contacts, after that the starter caught on first time every time, Its just a $10 relay but its easier to clean the contacts then to drive down to O'Riley to buy another relay.
That's great to know as a roadside fix! I just ordered mine off Ebay, delivered for $6.38. I think the starter relay may be more of a suspect than we maybe realize.

John
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  #20  
Old 26th October 2021
Akdawg Akdawg is offline
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At the Portland Airport I found that a paperclip will make an 85 XLH start....found a NAPA shortly after. Bought two, one for the tool bag
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