Electrical issue 04xl1200r
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4th Gear
Joined: May 2020
Posts: 8
Likes: 0
From: Hawaii
Electrical issue 04xl1200r
Hello everyone, long time listener, first time caller. My sporty has been down for a couple months and I'm at my wit's end with it. Recently replaced my stator, starter, and flywheel, and after putting everything back together, I've encountered a weird issue. When I attempt to reconnect the battery, the positive lead arcs like hell and instantly starts melting the terminal. Asking around people have told me I have a short, or my battery is bad. I've replaced with a new battery to no avail, and have yet to find a the short. It should be noted that this only happens when connecting the lead from the starter, the other line with the maxi fuse works fine. Due to the current lockdown I am also unable to take it to a shop, they're all closed around here and have a 6+ month backlog of repairs. Any help appreciated. Thanks!
Intermediate
Joined: May 2020
Posts: 33
Likes: 4
From: delaware
Hey man, i would just clean up any corrosion around the terminal and lead. Corrosion would cause this. I always get a bit of arcing when connecting my leads, just make sure the connection is tight and you should be good to go. I've had my battery terminals melt in the past due to a loose connection causing arcing. I just cleaned the leads and made sure the connection was tight on my new battery and it was fine from there.
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4th Gear
Joined: May 2020
Posts: 8
Likes: 0
From: Hawaii
Hey man, i would just clean up any corrosion around the terminal and lead. Corrosion would cause this. I always get a bit of arcing when connecting my leads, just make sure the connection is tight and you should be good to go. I've had my battery terminals melt in the past due to a loose connection causing arcing. I just cleaned the leads and made sure the connection was tight on my new battery and it was fine from there.
I thought that at first and have done that. This isn't just minor arcing like that. It's super hot and aggressive. The terminal bolt was too hot to touch for almost 10 minutes after less than a second of contact. Thanks for trying, this is driving me nuts
Intermediate
Joined: May 2020
Posts: 33
Likes: 4
From: delaware
A few more things to try is pull each fuse 1 by 1 and every time check to see if you get the same arc, if you don't with any of the fuses then investigate the module and connections it it. Also check your ground, see if you have a dead short, that would cause the issue you are experiencing. If you have a meter there are ways to test your entire charging system pretty easily. Also if you have a buddy with a sporty i'd swap voltage regulators with them (takes 20 seconds to swap) to see if that makes any difference. These HD charging systems have given me headaches on my sporty and dyna but its always something simple in the end. GL!
Outstanding HDF Member
Joined: Feb 2015
Posts: 2,414
Likes: 433
From: Arkansas
Sounds like the starter solenoid has a dead short to ground, you should be connecting positive first and then ground so as not to possibly short when connecting the positive. New starter so likely a new solenoid maybe bad from the manufacturer.
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