Help: too hard to start.

[jwh2573]

Hi fellows, got a great 1984 fxrdg. The motor has over 170lbs of compression in both cylinders and runs like no harley I have ever known. The problem is that I am tearing up starter solenoids every 2000 to 3000 miles. At times it gets so bad that the solenoid sticks and either continues to run or it jams and starts to melt my positive battery post. Any ideas other than installing compression relief valves would be appreciated. Thanks.

[RattFXR]

There are various remedies to your problem. first off, it sounds as if your Jackshaft assembly and bushings might be a little worn and binding, causing the plunger in the selonid to stay engaged. However, if your running a stock starter, go to a 2.0kw ultima with heavier cables and a good battery. I use a 275 amp from autozone and it's great. Another option is a camshaft with more overlap, which will allow more pressure to escape. Melting a post is a sign of inefficent battery cables and/or connection. Trying using a lock washer under the cable on the battery and clean up the ground contacts. Thats all you really can do besides compression releases. I have all the above and it still hangs on me once in a blue moon but always turns over hard. I'm using a 2.4 kw starter. Performance isn't easy, and never cheap! Try Jireh cycles for your parts though. Cheapiest, even if you know someone....

[jwh2573]

I have installed a 1.4kw starter with 4mm cables, wired it directly to the starter and used the shortest cables possible to reduce resistance, also went with a 350cca battery from big boar. I installed a brand new solenoid and it was o.k. for awhile. After 2000 to 3000 miles the solonoid starts to click real bad and I have to try and get the motor off of the compression stroke, which is very difficult to do since the bike is hard to turn over. Even when all these parts were brand new the bike at first push of the start button has a delay before it starts to spin. I try to reduce the amount of abuse to the solenoid by starting the bike in the off position then as it turns a couple of times I switch it to on to fire. This only delays the inevitable, when I dissassemble the solenoid it looks as if someone has been arc welding on my copper washer. Does anybody know of a high output solenoid? I did check the jackshaft and all is o.k., no binding.

[Grinder]

check ground strap under scoot.

[jwh2573]

Already did that. Clean ground and secure. Although all is not Lost. Got tired of worring if it was going to start or not. Almost left my wife and I high and dry at Mountainer casino last weekend. So we traded it in today at Liberty Harley here in Ohio. Bought a new '08 Heritage Softail Classic. Starting problem solved. Thanks for the input guys.

[RattFXR]

The "arc" welding is normal, that is from 300 amps touch soft metal. Once you stop getting the starter to turn, then that washer is probably worn out. One other thing to check/change, is the the starter clutch, which is can sound like a chattering noise. If that has gonna out, then that motor is not going to turn over. You can get a heavy duty starter clutch for fairly cheap (60 bucks) and that might fix your problem. Just pull that starter off, take the reduction gear pad off and there it is. Right where the splines go into the jackshaft assembly. Press it or tap it out, put the new one in. Make sure that the splined coupler that is in the inner primary (the 1in round guy) is not chewed up. If it is, it will cause binding, which will smoke check the starter clutch.