HARLEY SHOP TALK

Often Imitated, Never Duplicated

Welcome Guest ( Log In | Register )

 
Reply to this topicStart new topic
> '05 SPORTY 1200 XL CUSTOM / Just replaced starter not starting
NicoyaStyln
post Jan 17 2016, 11:30 PM
Post #1





Group: Members
Posts: 1
Joined: 25-January 15
Member No.: 7,362
BIKE: XL1200C Sportster 1200 Custom
YEAR: 2005
MILES: 13000



'05 SPORTY 1200 XL CUSTOM / Just replaced starter not starting


The starter was diagnosed faulty and needed to be replaced. Rather than repairing the starter I choose to buy a rebuilt/remanufactured starter from the Harley Dealership and replace it myself as I did not have $400-$500 to drop on a new HD starter.

I've replaced a starter before on a Sportster (another bike), followed the same steps from my first starter replacement on another bike, even pulled out my original owners repair manual for the '05 Model and followed the steps listed their as well.

Now, after replacing the starter + new primary & derby cover gaskets + new transmission oil + engine oil & oil filter + starter relay, my Sporty does not want to crank on.

This is what it is currently doing:
1. Key in ignition
2. Choke pulled out
3. Turn key to on position
4. Power comes on without hesitation
5. Push "on" button
6. Allow a couple of seconds to pass until engine light disappears from speedometer
7. Push "start" button
8. 1 click occurs but no winding or other sounds
9. After pushing "start" button attempt number 2 & 3, multiple clicks now occur but no winding or other sounds.

Notes:
*during the starting attempts power to lights & speedometer do not dim
*after failed attempts removed HD battery, took it to local auto parts shop where they tested battery and confirmed the battery is good but needs to be charged. It was at 12.36 Voltage, measured 207 CCA, and rated for 225 CCA.
*I charged battery on my tender for 1-2 hours, once charged I attempted to start bike up again and same results as the above #8 & #9.

During the starter replacement the only thing I was unsure about was when I was putting everything back together, new starter, new gaskets, new oil, primary back on, I was reconnecting all of the cables and that is when I had a brain fart and forgot but assume the ground (shown on the attached pictures) had 4 wires / 4 terminals on it. I checked to see if any of the other wires had enough length to land anywhere else but they didnt and I could only trace 2 of the 4 wires to its origin. Ground bolt on starter [1 negative thin wire from charger for tender, 1 negative thin wire going to module (show in picture) but am unsure what it is called, and 2 thicker wires / 2 terminals wrapped in the same conduit heading to the rear of the bike].

Need help, suggestions, recommendations, anything to help me troubleshoot this problem.

Thank you in advance!
Attached File(s)
Attached File  20160116_170339_resized.jpg ( 410.53k ) Number of downloads: 0
Attached File  20160117_214803_resized.jpg ( 346.12k ) Number of downloads: 0
Attached File  20160117_214832_resized.jpg ( 302.85k ) Number of downloads: 0
Attached File  20160117_215002_resized.jpg ( 375.41k ) Number of downloads: 0
Attached File  20160117_215049_resized.jpg ( 307.6k ) Number of downloads: 0
 
Go to the top of the page
 
+Quote Post
deuce04
post Jan 18 2016, 05:33 AM
Post #2



Group Icon

Group: BOTM Winner's Circle
Posts: 4,819
Joined: 5-May 05
From: CT
Member No.: 21
BIKE: FXSTDI Softail Deuce EFI
YEAR: 2004
MILES: 10
BIKE: FXSTDI Softail Deuce EFI



Is that spacer /washer behind the ground supposed to be in that position>
I have had a starter not work because the washer was in the wrong place.

Just an idea
Go to the top of the page
 
+Quote Post
Blackcloud
post Jan 18 2016, 07:22 AM
Post #3



Group Icon

Group: BOTM Winner's Circle
Posts: 12,716
Joined: 2-December 06
From: Sweet tea territory
Member No.: 1,370
BIKE: FLHTCUI Ultra Classic Electra Glide EFI
YEAR: 2009
MILES: 20,000
MILES: 50,500



The sporty I have is different. It's a 2011 883. My ground only has 1 cable going to it. There's what looks like another ground further in that has at least 1 more wire.
Go to the top of the page
 
+Quote Post

Reply to this topicStart new topic
2 User(s) are reading this topic (2 Guests and 0 Anonymous Users)
0 Members:

 

Lo-Fi Version Time is now: 22nd November 2017 - 06:54 PM
Harley Shop Talk Established 05/05/05
Painting By: Dave Barnhouse / Hadley House Publishing, All Rights Reserved
HARLEY SHOP TALK IS NOT AFFILIATED WITH HARLEY-DAVIDSON®, INC.
HARLEY SHOP TALK: IF WE AIN'T TALKIN' HARLEYS, WE'RE TALKIN' $#*%!