82 FXE Starter Problems...AGAIN!

[Tony S]

New Ultra, its me again...
I changed the Starter recently on my 82 Shovel & it just never seemed right. It would drag when I went to fire it up occasionally. Ya know how after you've been ridin' your bike all day & ya park for a couple minutes...then go to fire up the bike the starter drags a little because the bike is so hot. Thats what mine is doing when its cold...and ALOT!
SO THEN a couple days ago when I went to cold start it, it made rapid clicks like a low battery would make (battery is new) & then eventually engaged & fired up. Someone told me it was the solenoid so I bought a new one & a new starter relay at the same time. Today I installed the solenoid & the relay & its doing the exact same thing...rapid clicks & then just click, click, click. I have spent alot of money trying to correct this & frankly I'm out of patience & ideas. I hope I'm being clear on the problem...Any clues as to whats goin on with this electrical NIGHTMARE?
Thanks, Tony

[chopperb]

Check your cables. are they corroded? are they loose? Check those and get back to us.

[Tony S]

The cables are new, clean & tight...thanks for gettin' back so quick. T.

[Y2K]

What happens when you give it a jump?
If a jumper kicks it right off or charging your battery makes it fire I'd suspect a bad voltage regulator or maybe a bad stator.
Have you checked your stator out put?
You say the battery is new so I'd pull it , charge it up to full , see how it starts and then go from there.

[Tony S]

I charged the battery over night...its full up. The charging system is all good. It wont jump from the solenoid, just rapid fire clicking, the same as when I try it from the starter switch. Is there something I could have screwed up when changing the solenoid or is it basically a foolproof R & R? I'm talkin internally, not stuff like did I remember to replace the spring or did I remember the spacer? Yes, I did remember.
So the cables are new, clean & tight. The Voltage Regulator & Stator are good. There is a new, fully charged Battery. New Starter, New Starter Solenoid & New Starter Relay. The bike just WONT turn over. Any more suggestions?

[MilesToGo]

Originally Posted by Tony S

I charged the battery over night...its full up. The charging system is all good. It wont jump from the solenoid, just rapid fire clicking, the same as when I try it from the starter switch. Is there something I could have screwed up when changing the solenoid or is it basically a foolproof R & R? I'm talkin internally, not stuff like did I remember to replace the spring or did I remember the spacer? Yes, I did remember.
So the cables are new, clean & tight. The Voltage Regulator & Stator are good. There is a new, fully charged Battery. New Starter, New Starter Solenoid & New Starter Relay. The bike just WONT turn over. Any more suggestions?

Did you check the cable connections at the starter?

[Tony S]

Yes...everything is clean & tight.

[newultraclassic]

I would still check the charging voltage at the battery. Next time it starts, put a voltmeter on the battery and see if you have close to 14 volts DC. If it is charging and all is well in the system, then I really suspect the starter, although most of them are good when new.......

[Tony S]

Its puttin' out a little over 13 volts at 2000 rpm...
The problem seems to lie at the solenoid...now when I jump it at the solenoid it hits EVERYTIME. When I use the starter button it'll hit every so often. Is it possible I purchased a brand new faulty solenoid?????????

[Y2K]

Originally Posted by Tony S

Its puttin' out a little over 13 volts at 2000 rpm...
The problem seems to lie at the solenoid...when I jump it at the solenoid it fires up EVERYTIME. When I use the starter button it'll hit every so often. Is it possible I purchased a brand new faulty solenoid?????????

Yes it's possible especialy if it's some kind of china chrome brand.
One more possibilty is the starter button or ignition switch.
I had the same kind of trouble with a '89 FLHT and it turned out to be the ignition switch,something about leaking voltage as I recall.

[Tony S]

Yeah...its a "Dixie Distributor" brand, chrome aftermarket, made in Tawain piece of CRAP...Never again will I skimp on parts for my scoot...MY BAD!!
I will check my starter button switch too...We're sure narrowing it down though!
I do want to thank everyone who has shot me some troubleshooting suggestions. I TOTALLY appreciate it.
I will go out & get a Genuine Harley Solenoid this week if the starter button checks out...Hell, I'll get one anyway...I dont want that sh!# on my bike.
I'll probably update everyone once my bike is right.
Thanks again, Tony

[BIBS]

I had a similar situation with a 66 slabside shovel I built over 6 years ago.....I finally went with a spyke starter and ran a "jumper" ground wire....4# gauge as close to the starter housing as I could get....no more starting problems.It,s fair to say that all the electrical components were new and american made at that.

[newultraclassic]

Originally Posted by Tony S

Yeah...its a "Dixie Distributor" brand, chrome aftermarket, made in Tawain piece of CRAP...Never again will I skimp on parts for my scoot...MY BAD!!
I will check my starter button switch too...We're sure narrowing it down though!
I do want to thank everyone who has shot me some troubleshooting suggestions. I TOTALLY appreciate it.
I will go out & get a Genuine Harley Solenoid this week if the starter button checks out...Hell, I'll get one anyway...I dont want that sh!# on my bike.
I'll probably update everyone once my bike is right.
Thanks again, Tony

Hello again,

You may well be able to purchase a "genuine Harley solenoid" from the dealer but you may well be in for a shock. My guess would be that they are also made in China.

The problem is that the Shovelhead hasn't been built since 1983 or 1984, depending upon who you are talking to. HD does stock some parts but with the passage of time they have dropped most of the Shovelhead parts. The ones they do have come from various sources.

I'm not sure whether you have a service manual. The 1978-1 /2 service book covers disassembly and testing of the solenoids and they are pretty straightforward. I'd be certain that you have a bad one before you spend any more money.

Good luck.

[Tony S]

New Ultra, the box that my solenoid came in reads... solenoid swtch,zinc plated. Made in United States.
Regards, Tony

[newultraclassic]

Originally Posted by Tony S

New Ultra, the box that my solenoid came in reads... solenoid swtch,zinc plated. Made in United States.
Regards, Tony

Good. You lucked out. The solenoid I have is Chinese and it's been running for years.