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  #11  
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rugger2 rugger2 is offline
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Good result after taking all of the advice given. My bike is no longer dead but all electrics back up and functioning except the starter. Solenoid clicking. Battery started at 12.8 v but volts dropped to 9 almost immediately. New battery next. Thanks to all of you for the good advice. Problem was one wire. Replaced and bike electrics are working.
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Could your solenoid be bad? Can you short across with a pair of needlenose it to see if the starter turns over?


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  #13  
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Always nice to get some feedback to the forum. Maybe it will help someone in the future with the same problem. Good to hear everything is working again!

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Quote:
Originally Posted by rugger2 View Post
Good result <SNIP> New battery next.

Thanks to all of you for the good advice. Problem was one wire. Replaced and bike electrics are working.
Great to hear nothing actually was killed but the wire...

This might be a good time to upgrade the battery cables (as mentioned in the previous SP link) if your's are somewhat worn or corroded...

When you get the new battery, be sure to charge it up before using it (or have it charged by the store) - Measure the voltage as a reference before putting it in the bike...

Take the 4 meter readings - (1-KeyOff, 2-KeyON, 3-CrankingStarter & 4-Running/Charging) - Keep those measurements as a reference for the future...

If there are still issues with the starter, here's the Sportsterpedia section on that:
Sportsterpedia - Starter & Solenoid Assembly


Thanks for the update - it always helps to have these threads with proper endings...


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  #15  
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I should have mentioned the problem wire was the one that runs from the positive post on the solenoid to the main breaker. I had no voltage at the circuit breaker as this wire burnt somewhere inside. New, heavier wire and all is good. The battery cables had been replaced earlier.
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  #16  
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John Harper John Harper is offline
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Quote:
Originally Posted by rugger2 View Post
I should have mentioned the problem wire was the one that runs from the positive post on the solenoid to the main breaker. I had no voltage at the circuit breaker as this wire burnt somewhere inside. New, heavier wire and all is good. The battery cables had been replaced earlier.
Do you mean the positive post on the "battery?"

John
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No. The positive post of the battery has a cable that goes to the solenoid. There is another wire attached to the solenoid post that runs to the circuit breaker. It went when the battery leads were reversed.
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Quote:
Originally Posted by John Harper View Post
Do you mean the positive post on the "battery?"
It looks like 2004 was the first year that the Main CB/Fuse was fed directly from the battery - Prior to that, the battery connects (Large Cable) at the Starter Solenoid & then a smaller wire feeds from the sam solenoid terminal to the Main CB/Fuse...

Was yours wired differently, John?

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Yes it is!

From my positive battery post, one large cable goes to the starter, and a smaller red wire goes directly to the main CB. The only wire going to the starter solenoid is the one from the starter relay (dark green). Mine is stock 1991 as I am original owner. Of course, it's a very early production model, as I still had the sealed beam headlight, not the H4 capsule style.

I can see why they may have switched it to make it only one wire off the battery. That little red wire of mine is kind of a PITA to deal with at times. But, I installed a Shorai lithium battery 4 years ago, and have not touched the battery since!

The other side of the main CB goes to the ignition switch. The regulator wire attaches to the battery side of the CB, IIRC.

John
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Quote:
Originally Posted by John Harper View Post
I can see why they may have switched it to make it only one wire off the battery. That little red wire of mine is kind of a PITA to deal with at times.
Is that wire to the Main CB long enough to reach back down to the Starter Solenoid? Where the heavy Battery wire goes? You could move it there if it is long enough...

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