93 low rider electrical gremlins s
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Stage IV
Joined: Sep 2022
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From: Louisiana
93 low rider electrical gremlins s
What’s happening fellas,I’m new to HD forums and the owner of my second harley but first one I’ve worked on besides maintenance. It’s a 93 dyna low rider and I got it with all of primary and secondary disassembled and missing a good many parts in between. I’ve finally got everything together and ready to run, I hit the starter button and clutch cable burns up ( after a few attempts of pushing the button before I saw the smoke coming from the cable). But anyway, I’ve read the posts about the ground issues it could be. But when I put a ground from starter bolt to frame, it arced off. When I put a ground from starter bolt to negative post on battery. Burnedthe wire up. This is while hitting starter switch. I couldn’t find a ground strap and don’t know if my bike came with one and needing much appreciated guidance. Thanks in advance. (Ps. Could the front blinkers not being mounted but electrically hooked up be an issue?)
Grand HDF Member
Joined: Apr 2007
Posts: 3,727
Likes: 3,073
From: Brighton, MI
What gauge wire/cable are you using that is "burning off"? Start with the basics below:
You should have a cable from battery negative post to the a bolt on the frame. Another cable from one of the starter mounting bolts to the same bolt on the frame (or right next to it). The frame bolt for the cables is just above and to the right of the starter. The cables need a good clean solid connection. Check the cables for continuity.
I think factory is 6 gauge but 4 would be better if your replacing with new. In a pinch and while the quality is less than desirable, something from the auto chains would work for a temporary fix.
You also need look for a (black about 16 to 18 gauge) ground jumper wire going from frame to front triple tree and a black jumper from triple tree to to handle bar riser bolt.
Check starter relay. It is a bosch style cube relay is the fuse box location. It's best just to replace it.
Once that is done, if the problem persists, start looking for dead shorts.
You should have a cable from battery negative post to the a bolt on the frame. Another cable from one of the starter mounting bolts to the same bolt on the frame (or right next to it). The frame bolt for the cables is just above and to the right of the starter. The cables need a good clean solid connection. Check the cables for continuity.
I think factory is 6 gauge but 4 would be better if your replacing with new. In a pinch and while the quality is less than desirable, something from the auto chains would work for a temporary fix.
You also need look for a (black about 16 to 18 gauge) ground jumper wire going from frame to front triple tree and a black jumper from triple tree to to handle bar riser bolt.
Check starter relay. It is a bosch style cube relay is the fuse box location. It's best just to replace it.
Once that is done, if the problem persists, start looking for dead shorts.
HDF Community Team
Joined: Dec 2005
Posts: 5,428
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From: NC USA
Wasn't sure exactly where the ground points were, so waited till someone else got that right for you. Thanks YD.
Assuming the battery cable ground connections are correct, clean and tight, the more I read about how it "lights up" everything, more I'm leaning to a short, probably in the solenoid.
If you can, take the short cable (from the solenoid) off of the starter motor and insulate it. Try the start button and see if you get similar or same results. If yes, then you can bet there is a short in the solenoid. They can usually be repaired if it's a damaged insulator. And could be the insulator on the motor stud itself.
Assuming the battery cable ground connections are correct, clean and tight, the more I read about how it "lights up" everything, more I'm leaning to a short, probably in the solenoid.
If you can, take the short cable (from the solenoid) off of the starter motor and insulate it. Try the start button and see if you get similar or same results. If yes, then you can bet there is a short in the solenoid. They can usually be repaired if it's a damaged insulator. And could be the insulator on the motor stud itself.
Last edited by t150vej; Sep 5, 2022 at 08:50 AM. Reason: correct
The fact that you ended up grounding through the clutch cable is consistent with a missing ground strap.
Grand HDF Member
Joined: Apr 2007
Posts: 3,727
Likes: 3,073
From: Brighton, MI
On your Dyna, the entire drivetrain (engine, trans, primary, swingarm) is vibration isolated from the frame, and therefore also electrically isolated. There needs to be a ground strap from the drivetrain to the frame.
The fact that you ended up grounding through the clutch cable is consistent with a missing ground strap.
The fact that you ended up grounding through the clutch cable is consistent with a missing ground strap.
There is also a jumper cable that goes from one of the starter bolts to the frame pretty close to the the negative cable attachment point. I think some years the cable eyelets share the same bolt. It has a pretty large loop to prevent work hardening of the copper because the engine does move on the rubber mounts.
The engine is actually grounded right there at the starter bolt. That ground carries thru the primary and the connection points of the primary bolts provide a ground for the trans and the engine. Your primary is one big electrical connector for ground.
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Stage IV
Joined: Sep 2022
Posts: 4
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From: Louisiana
Wasn't sure exactly where the ground points were, so waited till someone else got that right for you. Thanks YD.
Assuming the battery cable ground connections are correct, clean and tight, the more I read about how it "lights up" everything, more I'm leaning to a short, probably in the solenoid.
If you can, take the short cable (from the solenoid) off of the starter motor and insulate it. Try the start button and see if you get similar or same results. If yes, then you can bet there is a short in the solenoid. They can usually be repaired if it's a damaged insulator. And could be the insulator on the motor stud itself.
Assuming the battery cable ground connections are correct, clean and tight, the more I read about how it "lights up" everything, more I'm leaning to a short, probably in the solenoid.
If you can, take the short cable (from the solenoid) off of the starter motor and insulate it. Try the start button and see if you get similar or same results. If yes, then you can bet there is a short in the solenoid. They can usually be repaired if it's a damaged insulator. And could be the insulator on the motor stud itself.
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Seasoned HDF Member
Joined: Jul 2014
Posts: 8,610
Likes: 3,377
From: Cental, MI
On your Dyna, the entire drivetrain (engine, trans, primary, swingarm) is vibration isolated from the frame, and therefore also electrically isolated. There needs to be a ground strap from the drivetrain to the frame.
The fact that you ended up grounding through the clutch cable is consistent with a missing ground strap.
The fact that you ended up grounding through the clutch cable is consistent with a missing ground strap.
Also
Too small wire Gauge...or low voltage at battery, will cause Heat... Lots of it.
Last edited by Racepres; Sep 6, 2022 at 08:50 AM.
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