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  #101  
Old 16th September 2017
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sportsterdoc sportsterdoc is offline
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Sportster/Buell Model: 1200S
Sportster/Buell Year: 2002
Sportster/Buell Model #2: XLH883
Sportster/Buell Year #2: 2003
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dirt rider:
Got it running?
Voltages checked?
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  #102  
Old 16th September 2017
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dirt rider dirt rider is offline
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Sportster/Buell Model: XL1200R
Sportster/Buell Year: 2005
Sportster/Buell Model #2: BMWR100RT/K100RS/HondaCBX
Sportster/Buell Year #2: 8186
Other Motorcycle Model: Husky 07 510TE/ 16 TE300
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Just had lunch and an afternoon nap. Stator is in with clutch and flywheel installed. I work slow and methodical, carefully cleaning everything as I go. Might not be finished until tomorrow.
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  #103  
Old 17th September 2017
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Sportster/Buell Model: XL1200R
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Got it all together and is working well. Charging voltage at battery is 14.3 volts. It didn't take much electrical knowledge to see what was wrong. Potting material on regulator was cracked/crazed and wires at attachment point on stator had insulation baked hard and starting to fall off. I thank you for your help. It probably saved me $500.00. If you ever visit Shuswap Lake in central British Columbia, look me up and I will buy the beer. I was going to post a picture but I can't figure out how to do it.
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  #104  
Old 17th September 2017
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sportsterdoc sportsterdoc is offline
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Sportster/Buell Model: 1200S
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Sportster/Buell Year #2: 2003
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Quote:
Originally Posted by dirt rider View Post
Got it all together and is working well. Charging voltage at battery is 14.3 volts. It didn't take much electrical knowledge to see what was wrong. Potting material on regulator was cracked/crazed and wires at attachment point on stator had insulation baked hard and starting to fall off. I thank you for your help. It probably saved me $500.00. If you ever visit Shuswap Lake in central British Columbia, look me up and I will buy the beer. I was going to post a picture but I can't figure out how to do it.
Good!
Not a drinker, but appreciate the offer of hospitality.
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  #105  
Old 28th September 2017
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canoli canoli is offline
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Sportster/Buell Model: xlh1200
Sportster/Buell Year: 1992
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Quote:
Originally Posted by sportsterdoc View Post
Older bikes, such as ironheads (pre 86) and early EVO used more frame/motor grounds. A poor mount on a frame grounded regulator was/is an issue.

Newer models use more harness/chassis grounds. For one, the regulator has two black wires to stator, a red wire to battery and a black wire to chassis ground.

It does not matter, if you have typically less than ~0.1 ohm from device to battery negative post.

Sparkplug prongs ground through threads to motor/trans, which, in turn has a heavy ground cable to battery negative post

Does that explain sufficiently?
Yes it does thank you very much Doc.
Sorry I didn't reply sooner, there's been a lot going on at work. Hopefully it settles back down to the usual craziness in the next week. I hope all is well with you and yours!

So re: grounding - can a bad ground on the bike, a ground that's not part of the starting circuit, cause cranking problems? In other words does every ground on the bike need to be good for the bike to crank (not necessarily run but crank)?

Meanwhile ... the past 3 weeks while the weather was cooler (70s) the bike started beautifully, probably ~100 consecutive, trouble-free starts.

Then over the wknd it got hot again (mid-80s) and it was back to the solenoid clicking - or sometimes just total silence. After a bit of fiddling it starts - but I never can figure out which bit of fiddling does the trick.

Could the weather possibly be a factor? I know I'm "reaching" here...

I suppose even if cooler temps help somehow it's only masking the problem, whatever it is. It certainly acts and feels like a bad ground but hunting them all down, tracing wires thru the harness, etc. is a slow process for me.

Well thanks for reading my continuing tale of woe!
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  #106  
Old 28th September 2017
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Not every ground needs to be good.
I need to leave for a meeting, so no time right now to re-read, but have you checked coil resistances, when hot?
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  #107  
Old 1st October 2017
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Hmm no I haven't looked at the coIL yet...hopefully this wknd I'll have some time.
Thanks for the answer on the grounds I appreciate it!
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  #108  
Old 26th May 2018
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months later .... '92 XLH 1200 - I never did find a single cause for the "click of death" (or sometimes complete silence when I hit the starter button) but I learned a lot in the process.

After replacing all four CBs, the starter relay, the starter/solenoid and the battery cables the bike is much better. 9/10 times it starts on the first press.

The bike prob didn't need a new starter/solenoid but I love the way the All-Balls 1.4kW cracks to life. There's a very satisfying snap, which is great way to begin a ride.

I mostly just wanted to say THANKS to all you guys who chipped in your thoughts and advice, particularly SportsterDoc.

Happy riding everyone!
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  #109  
Old 26th May 2018
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Glad it is working out for you!
Rep points for the follow-through and feedback.
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  #110  
Old 10th July 2018
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Hey D0c. I am in the process of wiring in those lights we talked about earlier and a cell phone charger. Is there an easy way to hook them to a keyed power source rather than direct to the battery?
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