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  #1  
Old 15th July 2007
Gone Gone is offline
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Default Repairing green wire to starter

The wire that runs from the starter relay to the starter has broken off from the connector at the starter. Can I remove the connector by using pliers and pulling out or is there some type of latch that I need to release. What is the best way to repair this connection. Any help would be appreciated.

Allen
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  #2  
Old 16th July 2007
Dakin Engineering Dakin Engineering is offline
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Sportster/Buell Year #2: 1991
Other Motorcycle Model: Sportster XLH
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It's a 90 deg spade connector. Match it to new one. Crimp. Solder. Heatshrink is optional, but beware of grounding.

Sam
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  #3  
Old 16th July 2007
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chrishajer chrishajer is offline
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On a 2001, I think that is a straight white plastic (they also used black plastic) connector and there is indeed a little tab that you need to release on the top, to let it loose from the starter motor. I think Sam is right that it was a black 90 degree flag terminal, but they changed that around 1994 I think to this one with a little more positive engagement (it clicks in and does not fall out any more). If it's a straight connector (not a 90 degree black flag with the wire coming in the side), then there is a tab on the top that you depress with a tiny screwdriver then pull the connector out out of the starter motor mating connector.

If Gary is right and it's part of the starter motor, he has the right solution. I suspect though that the green wire just broke off or pulled out of the white plastic connector. Depress the tab, pull straight out on the connector, get a new connector (72291-94 I THINK), then cut off the corroded end of the green wire, strip back the insulation a little, and recrimp in the new connector.

If I am wrong, sorry for misleading you.

--Chris
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  #4  
Old 16th July 2007
Dakin Engineering Dakin Engineering is offline
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My information is dated (1991). I just didn't imagine HD ever getting that fancy.

Sam
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Old 20th July 2007
Gone Gone is offline
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Just wanted to say thank-you for the responses they were appreciated. I got it fixed. It was a connector.

Allen
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  #6  
Old 22nd July 2007
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chrishajer chrishajer is offline
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Quote:
Originally Posted by Dakin Engineering View Post
My information is dated (1991). I just didn't imagine HD ever getting that fancy.

Sam
Yeah, me either. Stuff was the same for 15 years, then they started changing stuff almost every year, just like the metrics.

--Chris
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  #7  
Old 23rd July 2007
bw9 bw9 is offline
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Ahhh, I love a happy ending!!!

BW
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