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15th July 2007
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Master Mechanic
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Join Date: Nov 2004
Posts: 261
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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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16th July 2007
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Senior Master Bike Builder
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Join Date: Nov 2005
Location: 100 yo shack in the country
Posts: 2,164 Sportster/Buell Model: XLH Sportster/Buell Year: 1987 Sportster/Buell Model #2: XLH Sportster/Buell Year #2: 1991 Other Motorcycle Model: Sportster XLH Other Motorcycle Year: 1995
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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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16th July 2007
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Senior Master Custom Bike Builder
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Join Date: May 2006
Location: West of Chicago, Illinois USA
Posts: 5,311 Sportster/Buell Model: Dead Hugger Sportster/Buell Year: 1988
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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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16th July 2007
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Senior Master Bike Builder
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Join Date: Nov 2005
Location: 100 yo shack in the country
Posts: 2,164 Sportster/Buell Model: XLH Sportster/Buell Year: 1987 Sportster/Buell Model #2: XLH Sportster/Buell Year #2: 1991 Other Motorcycle Model: Sportster XLH Other Motorcycle Year: 1995
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My information is dated (1991). I just didn't imagine HD ever getting that fancy.
Sam
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20th July 2007
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Master Mechanic
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Join Date: Nov 2004
Posts: 261
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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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22nd July 2007
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Senior Master Custom Bike Builder
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Join Date: May 2006
Location: West of Chicago, Illinois USA
Posts: 5,311 Sportster/Buell Model: Dead Hugger Sportster/Buell Year: 1988
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Quote:
Originally Posted by Dakin Engineering
My information is dated (1991). I just didn't imagine HD ever getting that fancy.
Sam
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Yeah, me either. Stuff was the same for 15 years, then they started changing stuff almost every year, just like the metrics.
--Chris |
23rd July 2007
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Chief Know It All
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Join Date: May 2005
Location: Des Moines, Iowa
Posts: 409 Sportster/Buell Model: XL1200C Sportster/Buell Year: 2005
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Ahhh, I love a happy ending!!!
BW
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