I see some have similar issues like I do with my 1984 FLTC the dreaded click! I just brought my solenoid 4 months and its back! I saw a post where Dr.Hess and Digger wrote up on adding an extra relay my wiring is different so I added a picture to show if I add an extra relay is it wired correctly? basically your just jumping an extra relay to the other correct? which makes it 60AMPS instead of 30? will I benefit from this? covered all my grounds batteries new and good adding a thicker gauge wire TAN one seems to thin for a good signal? and I also know plunger which the starter gear is attached to gets bound up sometimes it has the shovelhead bottom which they were notorious for. thinking maybe adding a lighter spring to the tip of slider rod where the copper washer is seems a bit to stiff to me? maybe someone could shed some light on this for me help appreciated

 

Never mind dont look right

 

Don't over think it … it's easier than you drew up … read the Sticky above about adding a second replay … the Sticky lays it all out … I've added the second replay to a few bikes, and it works every time ...

 

I put a new All ***** starter on my bike a couple weeks ago, and a new solenoid. The starter came with a shim to put in the in the hole that the spring/rod slide into. It makes the system put more pressure on the contacts. I would try that first. The shim was maybe 1/16" thick, and the diameter of the hole in the sliding part.

 

I have always had intermittent "dreaded click" issues with my 1993 FXSTS. This weekend I finally got around to running a 12 ga fused wire directly from the battery to the #30 post on the relay. Bingo! It hits every time now! I checked the factory lead with my voltmeter, and it was losing a full volt before it even had a load on it! I had already run a new 12 ga wire from the relay to the solenoid. For years it would burn the solenoid contact discs and I would have to refinish them about twice yearly. It just wasn't pulling the solenoid in hard enough to make good contact. I had even reverted to adding the "emergency button" solenoid cover so that I could manually engage the solenoid when it would act up. I'll leave that cover on, because after all it still is a 26 year old Harley........

 

Just fix what is broken. A relay is not going to do that.
Of course, if the relay is burnt up, put a new one in. The little start switch powers the little soliniod on the relay to pull in that contact.
That just pulls in the larger contact on the soliniod on the starter that throws the starter gear in and at same time the huge 200+ amp contacts that run the starter.

 

One of the first things I did to my 1996 was add the relay, then added a set of ground wires, from the - post on the battery, to the top of the engine, to the frame work for the fairing. Has worked since 2014.