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It is NOT the relay, never would be as your solenoid is pulling in. You are seeing a voltage drop across your solenoid primary connections.
Your solenoid mounting is roached. Not sure who made it but it's junk. It's not a missing spacer, it's in there, you can actually see it in the photo's if you zoom in. Get an OEM or and Accel one and you will be good to go.
New solenoid in the picture is an Accel. Harley website shows unavailable. Looks like I could probably get OEM from Ebay if it comes to that.
I actually have a second new Accel that I haven't tried yet. I thought I had cooked the first one when I hooked up the wires wrong so I ordered another. I'm not confident I was correctly testing solenoid resistance as the manual describes because I was getting the same readings on both the installed and uninstalled Accel. I didn't want to install the second one with the hope of returning it but I found out I can't return opened package electrical items. I will try the second one and see if alignment is any better. Hell it might even start! If not I'll start inspecting wiring.
I really apricate everyone's help. Hope everyone has a good safe weekend.
Hey @JHD1827 . It sounds like you’re having the same problem I had years ago with my ‘89 FLHTC. I did a lot of research and finally ran across the link below about adding a second relay to fix the “dreaded click”. I originally hooked it up according to the directions in post #1. I have since re-wired it per post #214. Adding that second relay fixed the problem and I haven’t had any issues since.
I would suggest reading through the whole thread as there may be tips & tricks that apply to your bike but not to mine. Good luck.
@JHD1827 Hey, dont leave us hanging. Did you ever figure out what the problem was?
Sorry. Haven't had much garage time. Thanks for checking on me!
I think I did figure out solenoid alignment. It looks like the mount on the Accel mounting bracket is slightly farther back. I basically need a larger spacer. Going to try adding some washers.
I did read through quite a bit of the double relay thread but haven't started looking at wiring just yet. Might be a little while before I can devote some time to it.
Sorry. Haven't had much garage time. Thanks for checking on me!
I think I did figure out solenoid alignment. It looks like the mount on the Accel mounting bracket is slightly farther back. I basically need a larger spacer. Going to try adding some washers.
I did read through quite a bit of the double relay thread but haven't started looking at wiring just yet. Might be a little while before I can devote some time to it.
NO NO NO
The double relay is for people too GD lazy to repair the ACC circuit, mostly on Tour models.. It was, for a time, the go to for starter issues on the '89-up starters. You don't need to waste your time researching that.
I put the other solenoid on and she fired right up! Took an additional 3 washers to square it up. Maybe it was the angle, maybe I cooked the first one when I hooked up the wires wrong, maybe it was just a bad solenoid... Going to put the seat on and go for a spin. Thanks again for everyones input!
Problem not solved. I got in 4 or 5 rides in town but last night things took a turn for the worse. Went on a short ride to meet some friends. I smelled something at a stop light on the way there but couldn't tell if it was the bike or another vehicle. Didn't notice any smell when I parked. When I went to leave I got the click no start and smelled it again. Burnt wires . Had to go home and get my truck. First time putting anything other than a dirt bike in the bed of this one. It's got a mild lift, bike high centered, had to winch it in with straps. Thankfully I had some help.
Disconnected the battery but haven't inspected anything yet. Pretty bummed. I'll share what I discover once I have some time to dig in it.
P. It's got a mild lift, bike high centered, had to winch it in with straps. it.
High centered? My trailer the frame hits cause ramp is to steep. What exactly happened and how did you winch? I been thinking of setting up a trailer to load bikes easier with atv winch and ramp. Wondered if the pull angle would work, if mounted to bed.
High centered? My trailer the frame hits cause ramp is to steep. What exactly happened and how did you winch? I been thinking of setting up a trailer to load bikes easier with atv winch and ramp. Wondered if the pull angle would work, if mounted to bed.
The ramp to tailgate angle was too steep. Frame rails on the bike got stuck on the tailgate and we couldn't push it any more. We wrapped a ratchet strap around the crash bar and the front tie off point in the bed. Only had to move it a few inches to get it to roll again. When I unloaded at home I was able to get the bottom of the ramp higher up in relation to the truck and had no issue rolling the bike off.
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. Had to go home and get my truck. First time putting anything other than a dirt bike in the bed of this one. It's got a mild lift, bike high centered, had to winch it in with straps. Thankfully I had some help. 
