To maybe help someone with this common issue on our old EVOs, I want to put this out there. ‘91 FLHTC

Been chasing start issues for some time. Learned about voltage drop months ago, which due to the age of our wiring, has proved invaluable. Through that knowledge I have replaced both battery cables. R & R corroded ground wire out of starter relay. But this week I replaced the 87 wire (relay to starter solenoid) AND the 12ga wire from main CB to starter motor (that piggybacks Red battery cable). BOOM! 87 was the culprit. Cranks every time and my voltmeter is now almost 13Vdc. Everything seems to be happier. I will add that when replacing 87, I hard wired the compression releases to it then on to the starter solenoid. Every one of these wires tested good (0.00 ohms resistance) but that means JS unless you test them under load. New wires baby!

Bottom line, there are a lot of very accessible wires (without doing open heart surgery) so why not take the time and replace these 30 y/o wires. You never know what’s corroded just enough to F things up. (I tested handlebar switches and felt they were good.) Will admit that when the front was opened up I replaced the four CBs any the 34 connector with a Deutsch, during the rebuild. But those wires behind the fairing will probably not corrode as fast as the ones down by the starter and starter relay, being less weathered.



Make sure you're using enough gauge, as I found a couple 18 ga improperly installed.

 

Can you briefly describe the starting issue you had? I am sure many who search will use your post as a reference/resource.

I agree with everything you say, but my approach was a little different. However your post has me thinking. I inspected, cleaned, and lubed all connection points, posts, and terminals. Replacing all breakers, the relay and any questionable connectors. That's including, disassembly cleaning, greasing and reassembly of all switches and switch contacts. Your solution is more thorough.

There is a seller on fleabay who stocks every single color coded wire you could imagine to match the original wiring harness colors. Matching up some of the OEM connectors is a little bit of a challenge, but with effort, can be found. However I agree with you, I like the Deutsch connectors. They are a better connectors than the AMP mate-n-lock on my 1994

 

Good morning. Love to have that Fleabay wire dudes name...Your method is sound. We’re all doing well keeping 30 y/o machines running I think, especially wiring. In my case, I had all major components new, so had a head start on solving.



Since the rebuild and new EVO install, plus new starter and starter relay, problems began. BTW battery new and charged...always!



-Ignition switch to IGN would sometimes be dead



-Start Switch would sometimes not activate starter, but generally give me a starter relay click. Sometimes I could also hear a CB up front trip during Start Switch activation. Then could hear it reset. Then the ultimate tell...intermittent compression release clicks, which didn’t dawn on me until later.



If I was a real builder, considering the other rotten Easter eggs I found on this bike, I would have completely rewired the thing. No frickin’ way. So I start chasing each circuit and inspecting/cleaning every connector I can reach within reason. What could I ‘make nice’ that I could easily reach behind the fairing and back at the starter relay area, not spending a lot.



After convincing myself the Emergency Stop switch and Starter Switch were cleaned and functional, I thought F-it and replaced the four CBs up front. Then that little Namz single wire connector, #34 in-line to pole #30 on starter relay, which I could spin with my fingers, to a Deutsch. That alone solved everything, for a few starts.



Back at the starter relay/main CB/battery area, I finally stumbled upon a load testing video. This knowledge eventually solved everything.



Found corroded: 1) both battery cables 2) starter relay ground...someone put an 18ga wire on that-UTF?...I replaced with 14ga 3) 12ga wire from main CB to starter motor (piggyback on the +batt cable), hard wiring compression releases to the #87 starter relay-to-starter solenoid with a Solar connector and splash of solder then shrink wrap.



Everything works great now. Had to be corroded wires...especially when the bad stuff happened ‘sometimes’...


I have no clue why Harley would put a connector here. Makes a point-of-failure…

New Deutsch

Two wires I replaced this week finally solved everything. The 87 and Main CB to starter motor

Those two wires made nice

 

LMFAO just noticed in video the voltage gauge didn’t come alive. I always have to tap it once. After all, it’s frickin’ 32 years old haha haha.

 

Well, I don't know if I am breaking any "rules" but this guy has been good to me with many purchases over the years. The best selection of electrical wire, connectors, etc. If you don't see it on his listings, just send them a message. Always fast shipping and good quality stuff. I have no financial gain or connection with him.

https://www.ebay.com/str/4rcustoms