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Checking solenoid grounds

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Old Jun 26, 2018 | 08:11 AM
  #11  
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There is no negative terminal on the solenoid, just 2 positive terminals as it is nothing more that a high amperage electro-magnetic switch. The windings get power from the relay and push the plunger up to engage the 2 hot leads which engages the starter as the starter is frame grounded. The chassis of the solenoid is grounded but there is no ground going to any of the terminals on the solenoid. See the attached file for details, this is out of my 2005 service manual but is still relevant.
 

Last edited by Zanthamos; Jun 26, 2018 at 08:31 AM.
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Old Jun 26, 2018 | 08:19 AM
  #12  
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The only connection to ground would be the windings via the chasis of the solenoid and this can be checked via the relay input to the chasis. You will get a resistance value as there is a coil windings there.
 

Last edited by Zanthamos; Jun 26, 2018 at 08:24 AM.
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Old Jun 26, 2018 | 08:30 AM
  #13  
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Cool, we're getting there.
There is no negative terminal on the solenoid
Of course there isn't, that's why the negative cable was hooked up to the starter post (GN 87 in your first drawing)
Postive cable was hooked up to (2) in your last drawing.

the only thing that would go to ground is the relay connection as this activates the windings.
That's very interesting. Relay connection (3) is measured to be grounded, as well as (1) with cable (1) disconnected. (All in last drawing)
(3) is connected internally to (1), is that correct ? Or should this be an open circuit when not activated ?
 
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Old Jun 26, 2018 | 08:33 AM
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That would definitely cause a spark show if your rubber was worn out on the contacts and it was touching the case.
 
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Old Jun 26, 2018 | 08:36 AM
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3 and 1 aren't connected. 3 goes to the electro-magnet windings and 1 is nothing more that one of the posts to provide power to the starter.
 
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Old Jun 26, 2018 | 08:47 AM
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Damnit. So it's shorted.
I figure I need to replace the whole starter unit ?

Sadly I already checked all isolators and all are in pristine condition. (And ground remains)
 
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Old Jun 26, 2018 | 08:50 AM
  #17  
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To clarify, 3 -> 4 show continuation, resulting in 2 -> 5 being connected
 
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Old Jun 26, 2018 | 10:48 AM
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The 2 should be separate circuits, unless Harley has done something weird with the solenoid.The plunger should only contact the two main lines to power the starter.
 
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Old Jun 26, 2018 | 01:37 PM
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Thanks for sharing your thoughts !
Anyone with a similar bike or seperate starting who is willing to take the measurement ?
To make sure we've got it right before getting a new starter.
 
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Old Jun 26, 2018 | 03:29 PM
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Originally Posted by Zanthamos
3 and 1 aren't connected. 3 goes to the electro-magnet windings and 1 is nothing more that one of the posts to provide power to the starter.
Wouldn't they show continuity because they both ground to the case?
 
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