Won't start after pinching (and repairing) starter switch wire

[Sumitagarwal]

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?

[Maxeffort]

Originally Posted by Sumitagarwal

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.

[Sumitagarwal]

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.

[IXL2Relax]

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!

[Sumitagarwal]

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...

[sportsterpaul]

A great bonding moment, continue.

[farmall]

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.