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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #11  
Old 3 Weeks Ago
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I had a similar issue a couple of years back. New battery, cables, ect. No improvement. Checked the solenoid contacts and found that was the problem, burned and pitted. New parts were less than 25$ and problem solved.
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  #12  
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0.09 ohms from battery to starter motor. My fault there, I have come to assume most people have no clue there is a difference between an engine and a motor.

For the record, I measured at the studs for any of these tests involving a case ground because it’s a convenient point which allows for a probe to be clipped. Continuity is fine. I only mention it because it’s a steel stud and we’re talking about small numbers that probably aren’t the most accurate with this meter to begin with. However, the stud being conductive is pretty much irrelevant in operation. The terminals are between the flange and the case, not fixed to the stud.
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I always visually inspect solenoid contacts when I've a start problem since even if they're obviously not the cause they're usually worn and don't pass enough current.

No/low measured resistance through the contacts mean they have continuity, not ampacity. (A single strand of wire or contact area of that diameter will ohm good.) I'd remove the solenoid end cover and do a visual inspection. I expect every contact set I inspect that's more than a few years old to need replacement. HD starters work harder than the same excellent OSGR starter in a car not least because motorcycle batteries are tiny. I keep a couple of kits in my spare stash for my fleet and customer bikes.

This is a good time to install a pushbutton solenoid end cover as backup since they bypass all the control circuitry including the solenoid windings.

You'll need a primary cover gasket/seal kit, a starter gasket (I buy the five packs since they're cheap), and a contact kit. The kind to get include the solenoid core which has a ring shaped contact. You can often clean those up but I replace them. The kits are about cheap. Any kit this complete will be fine:

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

Any excuse to upgrade power and ground cables is a good one. I make mine using light gauge welding cable (local welding supplier will cut to length), lugs (nominal battery lug bolt hole ID is 1/4") and heat shrink tubing. Welding cable is high ampacity due to being fine stranded (more densely packed conductors for a given diameter), has excellent insulation and is designed to be flexible.

Good photo set on OSGR contact replacement. I eyeball the contacts for flatness instead of using a press since it's so easy to do. The old nuts are often seized to the studs. I cut those off with a zip disk.

https://expeditionportal.com/forum/t...acement.12746/
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  #14  
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Quote:
Originally Posted by sml1226 View Post
0.09 ohms from battery to starter motor.
Then starter solenoid is #1 suspect.
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