The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Era Specific and Model Specific > Frame Mount EVO Sportster Talk (1986-2003 models)
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Active Threads
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 5 Minutes Ago
Replies: 14,434
Views: 1,343,988
0 Fitment between 2005 & 2006
Last Post: Cindy Dietz
Posted On: 13 Minutes Ago
Replies: 30
Views: 1,563
0 DK Custom '19 Summer Adv. Riding to where Titanic Sank -Newfoundland Island & More
Last Post: DK Custom
Posted On: 15 Minutes Ago
Replies: 95
Views: 3,013
0 Mild 1250 build thoughts?
Last Post: aswracing
Posted On: 19 Minutes Ago
Replies: 80
Views: 2,345
0 Hot Rods, Rat Rods, and Customs.
Last Post: Graywolf
Posted On: 24 Minutes Ago
Replies: 3,730
Views: 457,321
0 Gerbing Heated gear sale
Last Post: Cindy Dietz
Posted On: 38 Minutes Ago
Replies: 0
Views: 1
0 Carburetor opinions
Last Post: juzyHD
Posted On: 42 Minutes Ago
Replies: 21
Views: 446
0 HD by Italian east coast
Last Post: Nibelungen
Posted On: 1 Hour Ago
Replies: 4
Views: 62
6 SPORTY BOBBER PICTURES
Last Post: Lone Rider
Posted On: 2 Hours Ago
Replies: 6,021
Views: 5,447,906
0 Wet Sump Ifo, fix and tools
Last Post: ryder rick
Posted On: 2 Hours Ago
Replies: 49
Views: 3,357
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 3 Hours Ago
Replies: 45,220
Views: 7,132,123
0 Iree's late night cafe
Last Post: Graywolf
Posted On: 3 Hours Ago
Replies: 1,318
Views: 166,508
0 foo foo foo foo
Last Post: ryder rick
Posted On: 4 Hours Ago
Replies: 2
Views: 110
0 Hello from Az
Last Post: Fiachra
Posted On: 4 Hours Ago
Replies: 14
Views: 153
0 Hot Chicks on Hot Bikes
Last Post: trainman
Posted On: 4 Hours Ago
Replies: 10,315
Views: 1,786,440
0 Keep & Kill
Last Post: Toejam503
Posted On: 4 Hours Ago
Replies: 13,941
Views: 781,794
0 Clean my Clock
Last Post: Toejam503
Posted On: 5 Hours Ago
Replies: 7
Views: 252
0 IT"S "dodgetrucken"s BIRTHDAY!!!
Last Post: Toejam503
Posted On: 5 Hours Ago
Replies: 0
Views: 54
0 Need help desperately rewiring the front of my bike
Last Post: HDCUSTMBUILD
Posted On: 5 Hours Ago
Replies: 3
Views: 150
0 Roads I'd like to ride.
Last Post: Stairman
Posted On: 6 Hours Ago
Replies: 2,480
Views: 208,604
0 Wiring Diagram in autocad
Last Post: Folkie
Posted On: 8 Hours Ago
Replies: 88
Views: 45,092
0 Want to buy broken clutch hub for 84-90 sportster
Last Post: rokytnji
Posted On: 8 Hours Ago
Replies: 6
Views: 456
0 This week on Craig's list
Last Post: Coz
Posted On: 8 Hours Ago
Replies: 4,369
Views: 522,804
0 IH sidecar road racer
Last Post: rokytnji
Posted On: 8 Hours Ago
Replies: 2
Views: 192
0 XLCH Crazy voltage spike
Last Post: Seeny
Posted On: 8 Hours Ago
Replies: 25
Views: 1,381
0 1960 XLCH in the UK
Last Post: spacecoast
Posted On: 9 Hours Ago
Replies: 150
Views: 14,095
0 Another ultima iggy query.
Last Post: the yukon sizzler
Posted On: 10 Hours Ago
Replies: 25
Views: 1,059
0 Transformer XR1200
Last Post: Bryan1976
Posted On: 16 Hours Ago
Replies: 99
Views: 8,151
0 Transmission Issue or clutch?
Last Post: Iron Mike
Posted On: 17 Hours Ago
Replies: 20
Views: 909
0 rotating engine by hand
Last Post: Hippysmack
Posted On: 17 Hours Ago
Replies: 3
Views: 77
More...
Members Birthdays
irvingjr (71), 909XR (62), Ghost_FL (60), mark R (59), TWISTED (46), spade (44), Drivethis29 (39), dodgetrucken (34)
Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #1  
Old 1 Week Ago
Sumitagarwal Sumitagarwal is offline
Biker
 
Join Date: Jan 2013
Posts: 50
Sportster/Buell Model: N/A
Sportster/Buell Year: N/A
Reputation: 2580
Sumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the rough
Default Won't start after pinching (and repairing) starter switch wire

Stupid me put some clip-ons onto the bike which worked out ok, but when I tried rotating the controls for better positioning I ended up pinching the starter wire (white + grey) with one of the bolts.

BAM, the bike no longer attempts to start. All other buttons still work. I found the pinch and repaired the wire with a red butt connector and crimp tool. Still no-go. Tried replacing the starter relay with this replacement: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 Still nothing. Thought maybe I might have tugged on the wire too hard during repair so carefully checked inside the right-hand control but the wire was still snugly connected, and checked the connector inside the headlight housing and it was still solid there.

Any other thoughts on here? Its a 2003, so I don't *think* there's any security module considerations I need to track down. Do 2003's have a bank/tilt sensor? I don't think so, but if so should I be checking something there?
Reply With Quote
  #2  
Old 1 Week Ago
Maxeffort's Avatar
Maxeffort Maxeffort is offline
Momentary Specialist
 
Join Date: Aug 2016
Posts: 464
Sportster/Buell Model: XL1200
Sportster/Buell Year: 1996
Other Motorcycle Model: ST1100
Other Motorcycle Year: 1999
Reputation: 664736
Maxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond repute
Default

Quote:
Originally Posted by Sumitagarwal View Post
Stupid me put some clip-ons onto the bike which worked out ok, but when I tried rotating the controls for better positioning I ended up pinching the starter wire (white + grey) with one of the bolts.

BAM, the bike no longer attempts to start. All other buttons still work. I found the pinch and repaired the wire with a red butt connector and crimp tool. Still no-go. Tried replacing the starter relay with this replacement: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 Still nothing. Thought maybe I might have tugged on the wire too hard during repair so carefully checked inside the right-hand control but the wire was still snugly connected, and checked the connector inside the headlight housing and it was still solid there.

Any other thoughts on here? Its a 2003, so I don't *think* there's any security module considerations I need to track down. Do 2003's have a bank/tilt sensor? I don't think so, but if so should I be checking something there?

Check the 15a ignition fuse. Check there is power on the gray wire.
Unplug the Deutsch connector and test with an ohmeter if the starter switch and the emergency stop (kill) switch are working at that point. (You can also back probe the Deutsch connected with a paper clip to perform voltage tests).

If that is good, use the schematic and keep working back.


__________________
Sleepy Labeef rides again!
Reply With Quote
  #3  
Old 1 Week Ago
Sumitagarwal Sumitagarwal is offline
Biker
 
Join Date: Jan 2013
Posts: 50
Sportster/Buell Model: N/A
Sportster/Buell Year: N/A
Reputation: 2580
Sumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the rough
Default

Thanks for those starting points and for the great wiring schematic! Much better and clearer than the schematics I'd seen so far.

I'll be trying out your suggestions in the morning.
Reply With Quote
  #4  
Old 1 Week Ago
IXL2Relax's Avatar
IXL2Relax IXL2Relax is offline
XL FORUM TEAM MEMBER
 
Join Date: Feb 2013
Location: Let Freedom Ring in PA
Posts: 6,815
Sportster/Buell Model: Sportster 883►1200
Sportster/Buell Year: 1994
IXL2Relax has disabled reputation
Default

On a 2003, the Bank Angle Sensor (BAS) controls the ground of the Starter Relay...

The Keyswitch feeds power to the Ignition Fuse on the RED/Black wire
The Ignition Fuse feeds power to the RUN/STOP Switch on the GRAY wire
That switch feeds power (in the RUN mode) to the Start Button (internal jumper)
The Start Button (when pressed) feeds power to the Starter Relay Coil on the BLACK/Red wire

Starter Relay Pins:

Coil
86 - is BLACK/Red from the Starter Button
85 - is BLACK from the BAS
Contacts
30 - is RED/Black directly from the Keyswitch
87 - is GREEN going to the Starter Solenoid
87A is not used - No Connection

You should use a multimeter set on 20vDC to check for power at each of the devices...

Here's the Sportsterpedia section on the Starter:
http://sportsterpedia.com/doku.php/t...k:evo:engctl02

And a simplified diagram of the starter relay wiring:


However...
When you're having issues with the electrical system, use this Sportsterpedia section about
checking the battery cables, voltages and grounds - DO THIS BEFORE ANYTHING ELSE:
http://sportsterpedia.com/doku.php/t...place_to_start


IXL _______ >>>> My Motorcycle Chronicles Are Here <<<<
For FREE Sportster Tech Info from the XLForum:
Explore The Sportsterpedia - The Best Kept Secret on the XLForum!
__________________
### The ride is more enjoyable to nowhere in particular! ###

Last edited by IXL2Relax; 1 Week Ago at 01:43..
Reply With Quote
  #5  
Old 1 Week Ago
Sumitagarwal Sumitagarwal is offline
Biker
 
Join Date: Jan 2013
Posts: 50
Sportster/Buell Model: N/A
Sportster/Buell Year: N/A
Reputation: 2580
Sumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the roughSumitagarwal is a jewel in the rough
Default

Oh dear god am I stupid! But also now finally happy...

So Maxeffort's initial suggestion was so simple that I went and tried it now. I had read so many horror stories about the starter relays that somehow I had never even bothered to check the ignition fuse. Sure enough, it was blown, and as soon as I swapped it it fired right up!

Of course that was after I had already completely disassembled the hand controls, headlight, and torn apart my cable repair because I assumed I'd made a mistake there...
Reply With Quote
  #6  
Old 1 Week Ago
sportsterpaul's Avatar
sportsterpaul sportsterpaul is offline
XL FORUM TEAM MEMBER
 
Join Date: Jan 2009
Location: In a swamp/Michigan
Posts: 13,807
Sportster/Buell Model: XL1460C
Sportster/Buell Year: 2000
Sportster/Buell Model #2: XL1200R
Sportster/Buell Year #2: 2006
Other Motorcycle Model: XL1200R
Other Motorcycle Year: 2004
Reputation: 10071290
sportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond repute
Default

A great bonding moment, continue.
__________________
I.B.A.#26543, Growing old-Mandatory/ Growing up-optional. Men do not quit playing because they get old, they get old because they stop playing!

The XL Forum Sportsterpedia:
http://sportsterpedia.com/doku.php/start
Reply With Quote
  #7  
Old 1 Week Ago
farmall farmall is offline
Flat Track Racer
 
Join Date: Jul 2013
Posts: 235
Sportster/Buell Model: XLH
Sportster/Buell Year: 73
Reputation: 407738
farmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond repute
Default

This is a good time to order a cheap pushbutton solenoid end cover. They're great backup because they bypass the solenoid windings and the external starter control circuit.

This style worked well for me but so do others as there is little to them.

https://www.ebay.com/itm/Pyramid-Pus...-/222536275694

Do a visual inspection on your starter contacts while you have the cover off. The starters are "Denso OSGR Light Duty" style used on millions of autos which means your local auto electric supplier/starter rebuilder can easily get contacts as they are not just "motorcycle" parts.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 21:51.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC