Starter isn't working
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Seasoned HDF Member
Joined: Nov 2006
Posts: 5,878
Likes: 1,893
From: East Coast, USA
Starter isn't working
Hello,
I'm in the process of performing a number of maintenance items on my 1993 Fatboy. One of the maintenance items I took care of this week was installing the HD starter solenoid rebuild kit (HD #31604-91A). I've installed this same solenoid rebuild kit on my 2011 Ultra last year without any issues.
Now, when I try to re-start the Fatboy. I hear what sounds like the solenoid engaging, but nothing else. The starter motor doesn't spin. Battery is good. I'm seeing about 11.5 volts when I push the starter button. Where do you suggest I start to diagnosis this issue?
I'm not looking forward to pulling everything apart again. To get the starter out, I had to:
1. Remove rear exhaust
2. Remove outer primary.
3. Remove jackshaft
4. Remove battery
5. Remove debris deflector
6. Remove fasteners from oil tank to give me enough room to pull out the starter
I'm in the process of performing a number of maintenance items on my 1993 Fatboy. One of the maintenance items I took care of this week was installing the HD starter solenoid rebuild kit (HD #31604-91A). I've installed this same solenoid rebuild kit on my 2011 Ultra last year without any issues.
Now, when I try to re-start the Fatboy. I hear what sounds like the solenoid engaging, but nothing else. The starter motor doesn't spin. Battery is good. I'm seeing about 11.5 volts when I push the starter button. Where do you suggest I start to diagnosis this issue?
I'm not looking forward to pulling everything apart again. To get the starter out, I had to:
1. Remove rear exhaust
2. Remove outer primary.
3. Remove jackshaft
4. Remove battery
5. Remove debris deflector
6. Remove fasteners from oil tank to give me enough room to pull out the starter
HDF Community Team
Joined: Dec 2005
Posts: 5,374
Likes: 2,570
From: NC USA
Unless that's exactly what it was doing before, I'd start at where with the last thing you did - the solenoid.
And a low or weak battery is always suspect, though 11.5 on the factory gauge sounds about right when pulling the solenoid only.
And a low or weak battery is always suspect, though 11.5 on the factory gauge sounds about right when pulling the solenoid only.
Thread Starter
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Seasoned HDF Member
Joined: Nov 2006
Posts: 5,878
Likes: 1,893
From: East Coast, USA
I think my issue has something to do with the jackshaft. Maybe I installed something incorrectly.
If I remove the outer primary, is it OK for me to try and start the bike and see if the jackshaft extends to the ring gear?
Seasoned HDF Member
Joined: Oct 2015
Posts: 13,403
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From: Pine Flat Dam/South Bay Area, CA
Remove the end cap from the solenoid housing and check to see if the stationary contacts have been installed level and the round copper contact on the solenoid plunger is engaging both of them and making a solid connection. You won't need to remove the starter to do this, but be sure to disconnect the negative battery terminal first.
Thread Starter
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Seasoned HDF Member
Joined: Nov 2006
Posts: 5,878
Likes: 1,893
From: East Coast, USA
Remove the end cap from the solenoid housing and check to see if the stationary contacts have been installed level and the round copper contact on the solenoid plunger is engaging both of them and making a solid connection. You won't need to remove the starter to do this, but be sure to disconnect the negative battery terminal first.
While holding pressure on the plunger, tighten the nuts on the terminals. This will ensure alignment of the contact plates.
When I push in the plunger, it requires a considerable amount of force via my fingers. Is that normal?
I even installed the old plunger (with the spring), and it also requires a considerable amount of force to push in.
Thread Starter
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Seasoned HDF Member
Joined: Nov 2006
Posts: 5,878
Likes: 1,893
From: East Coast, USA
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Seasoned HDF Member
Joined: Oct 2015
Posts: 13,403
Likes: 34,307
From: Pine Flat Dam/South Bay Area, CA
Great idea! I removed the end cap. It does look like the contacts were installed level. I do recall and following the rebuild kit instructions which say:
While holding pressure on the plunger, tighten the nuts on the terminals. This will ensure alignment of the contact plates.
When I push in the plunger, it requires a considerable amount of force via my fingers. Is that normal?
I even installed the old plunger (with the spring), and it also requires a considerable amount of force to push in.
While holding pressure on the plunger, tighten the nuts on the terminals. This will ensure alignment of the contact plates.
When I push in the plunger, it requires a considerable amount of force via my fingers. Is that normal?
I even installed the old plunger (with the spring), and it also requires a considerable amount of force to push in.
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Thread Starter
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Seasoned HDF Member
Joined: Nov 2006
Posts: 5,878
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From: East Coast, USA
I'll follow your suggestions tomorrow. Thank you!
It's just very frustrating since as I mentioned I've rebuilt the solenoid on one of these HD starters before, and I had the bike completely back together and was hoping to go for a ride.
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Seasoned HDF Member
Joined: Nov 2006
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From: East Coast, USA
One last question for this evening. Is it ok/safe for me to install the plunger (and return spring) back into the solenoid, re-attach my battery ground cable, turn on the ignition and push the plunger with a wooden dowel to see if the bike starts?
