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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 3 Weeks Ago
IXL2Relax's Avatar
IXL2Relax IXL2Relax is offline
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One more note of caution...

The two high current contacts (arc shaped) are mounted on the bolt that goes thru the body and on which are mounted the external wires - One wire is from the battery (incoming) and the other wire is to the actual starter motor (outgoing)...

When you tighten the wires onto these bolts IT IS POSSIBLE to (accidentally) rotate those internal contact surfaces and get them out of square with the plunger ring - which will then cause the contact area to be very small - this will cause pitting very quickly as a lot of current is now being funneled thru that small contact area...

If possible, it's best to mount the wires on those high current posts before you close the end of solenoid - This will allow you to press the plunger (by hand) down against those contacts while you tighten the nuts for the wiring... You can also visually see if the contact points are square to the plunger ring...

See the two contacts, each labeled 'B", in the picture at the Sportsterpedia page:
http://sportsterpedia.com/doku.php/t...k:evo:engctl02

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  #12  
Old 3 Weeks Ago
owlsplace owlsplace is offline
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Originally Posted by IronMick View Post
Be careful with that dielectric grease. It does not conduct electricity so you have to be careful where you use it. Use none on electrical connections.
Yes and no, sort of... It is commonly used in plug boots and coil towers. Years ago when I was doing 2-way radio we used it in the antenna connectors to weatherproof them.
On bulb bases:
https://itstillruns.com/apply-dielec...e-5621534.html
Wiki:
https://en.m.wikipedia.org/wiki/Sili...lectric_grease

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  #13  
Old 3 Weeks Ago
owlsplace owlsplace is offline
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Sportster/Buell Model: XLH 1000cc
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Originally Posted by IXL2Relax View Post
One more note of caution...

The two high current contacts (arc shaped) are mounted on the bolt that goes thru the body and on which are mounted the external wires - One wire is from the battery (incoming) and the other wire is to the actual starter motor (outgoing)...

When you tighten the wires onto these bolts IT IS POSSIBLE to (accidentally) rotate those internal contact surfaces and get them out of square with the plunger ring - which will then cause the contact area to be very small - this will cause pitting very quickly as a lot of current is now being funneled thru that small contact area...

If possible, it's best to mount the wires on those high current posts before you close the end of solenoid - This will allow you to press the plunger (by hand) down against those contacts while you tighten the nuts for the wiring... You can also visually see if the contact points are square to the plunger ring...

See the two contacts, each labeled 'B", in the picture at the Sportsterpedia page:
http://sportsterpedia.com/doku.php/t...k:evo:engctl02

IXL _______ >>>> My Motorcycle Chronicles Are Here <<<<
For FREE Sportster Tech Info from the XLForum:
Explore The Sportsterpedia - The Best Kept Secret on the XLForum!
Great info on those links. Wires passing through metal on vibrating machinery are a constant source of problems.
I put a hot-button on this solenoid before installing. It was good to take it apart and see how riding in the rain affected it. I also put silicone grease on and in the rubber boot protecting the high current connection to the starter.


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