At my wit's end
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Seasoned HDF Member
Joined: Jun 2015
Posts: 10,289
Likes: 7,773
From: West Central FL
At my wit's end
Still fighting that damn click and grunt B.S. on my '93 FLSTC. So far I've changed the starter relay twice, replaced the start button and kill switch assembly, rebuilt the solenoid on the original starter, installed a new starter, installed a new set of battery cables, new set of plug wires and on my third battery in two years. The positive terminal got so hot recently trying to start it that it melted a little! WTF is causing such a heavy draw??? I even put a heavier wire from the relay to the starter but when I checked the voltage at the starter I'm only getting five volts when the button is pushed!
Compression is 120lbs front jug and 122 rear jug. Could it be a timing issue? I dumped the bike off at the shop for a day and a half a couple of months ago and even they couldn't figure it out. I swear this evo POS has given me more grief in five years than my Shovelhead did in 36!
I can't even sell the damn thing because I don't want to just dump the problem on somebody else. WHAT AM I MISSING?
Compression is 120lbs front jug and 122 rear jug. Could it be a timing issue? I dumped the bike off at the shop for a day and a half a couple of months ago and even they couldn't figure it out. I swear this evo POS has given me more grief in five years than my Shovelhead did in 36!
I can't even sell the damn thing because I don't want to just dump the problem on somebody else. WHAT AM I MISSING?
Seasoned HDF Member
Joined: Mar 2010
Posts: 38,592
Likes: 6,435
From: Honah Lee
Lot of choices were to start since you have rebuilt everything and still got a replacement part that is bad.
Assume that new starter came with a new solenoid. But that melt on battery says load like that comes from bad rebuilding of a starter or a bad new starter...
Get a clamp over DC amp meter and clip on position battery terminals. Hit Starter and see what you get.
Maybe 150 amp. Sounds like you are drawing 400 amps to melt lead .
Motor turn over ok in high gear turning rear tire?
Assume that new starter came with a new solenoid. But that melt on battery says load like that comes from bad rebuilding of a starter or a bad new starter...
Get a clamp over DC amp meter and clip on position battery terminals. Hit Starter and see what you get.
Maybe 150 amp. Sounds like you are drawing 400 amps to melt lead .
Motor turn over ok in high gear turning rear tire?
Club Member
Joined: Sep 2010
Posts: 15,435
Likes: 7,127
From: Beyond Fucital
Follow all the wiring from the ignition to the plug under the tank then up to the bars and back to the little cube relay. Checking the voltage in all of the places to see where you lose it.
If youre getting some voltage but not all the voltage its probably a bad connection in the loop.
If youre getting some voltage but not all the voltage its probably a bad connection in the loop.
Stellar HDF Member
Joined: Apr 2016
Posts: 3,323
Likes: 2,114
From: Masshole
Writing this from a Shovelhead perspective, no knowledge of EVO starting system, so take it with a grain of salt.
You said you put in a new starter, what brand/part number?
Do you have a ground right to the starter?
If you take the positive off the starter, press the start button, 12v or 5v?
If 5v, read it inlet to solenoid, 12v or 5v?
If 5v, read it at inlet of starter relay, 12v or 5v?
If 5v, bad battery cable.
If 12v everywhere with starter disconnected, I would really be looking at the ground to the starter.
You said you put in a new starter, what brand/part number?
Do you have a ground right to the starter?
If you take the positive off the starter, press the start button, 12v or 5v?
If 5v, read it inlet to solenoid, 12v or 5v?
If 5v, read it at inlet of starter relay, 12v or 5v?
If 5v, bad battery cable.
If 12v everywhere with starter disconnected, I would really be looking at the ground to the starter.
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Seasoned HDF Member
Joined: Oct 2007
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From: Decatur, Alabama
Year ago we were trying to set the timing on my ironhead. The old man was making the adjustments then I would try it. At one point, it wouldn't hardly turn over. I asked him about that and he said it was because of the timing. You may be on to something. Double check it and static time it. Hope that helps.
carl
carl
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Road Warrior
Joined: Apr 2012
Posts: 1,484
Likes: 272
From: Canton, GA
Have you replaced the keyed ignition switch? I cleaned that mechanical brass thing so many times….replaced it with a cheap unit from J&P and haven’t had that problem since….
https://www.jpcycles.com/product/jp-...SABEgIIZfD_BwE
https://www.jpcycles.com/product/jp-...SABEgIIZfD_BwE
HDF Community Team
Joined: Dec 2005
Posts: 5,422
Likes: 2,621
From: NC USA
Still fighting that damn click and grunt B.S. on my '93 FLSTC. So far I've changed the starter relay twice, replaced the start button and kill switch assembly, rebuilt the solenoid on the original starter, installed a new starter, installed a new set of battery cables, new set of plug wires and on my third battery in two years. The positive terminal got so hot recently trying to start it that it melted a little! WTF is causing such a heavy draw??? I even put a heavier wire from the relay to the starter but when I checked the voltage at the starter I'm only getting five volts when the button is pushed!
Compression is 120lbs front jug and 122 rear jug. Could it be a timing issue? I dumped the bike off at the shop for a day and a half a couple of months ago and even they couldn't figure it out. I swear this evo POS has given me more grief in five years than my Shovelhead did in 36!
I can't even sell the damn thing because I don't want to just dump the problem on somebody else. WHAT AM I MISSING?
Compression is 120lbs front jug and 122 rear jug. Could it be a timing issue? I dumped the bike off at the shop for a day and a half a couple of months ago and even they couldn't figure it out. I swear this evo POS has given me more grief in five years than my Shovelhead did in 36!
I can't even sell the damn thing because I don't want to just dump the problem on somebody else. WHAT AM I MISSING?
Which post are you getting the 5 volt reading at?