Passes bench tests but not when installed
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5th Gear
Joined: Sep 2011
Posts: 9
Likes: 0
From: Henderson,NV
Passes bench tests but not when installed
Will a starter solenoid pass all bench tests but then click again once installed ? Power to everything,cheked and cleaned all connections,battery full charged. pull starter,passes all bench tests for solenoid out/hold/in,re-install and clicks again. Cleaned it all inside. Would a rebuild kit work or is a 16 yr. old starter too tired and need replaced ?
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,200
Likes: 3,089
From: NW AR
Yeah, it will do that. The Dreaded Click. Most likely not the starter or the solenoid, but the wiring and starter relay. Some of us have installed an auxiliary starter relay that has solved our problems.
Put a volt meter on the pull in connection (small wire) on the solenoid and measure the voltage when it is just clicking and not cranking. If it is less than the voltage at the battery terminal on the solenoid (big wire from the battery) by much, that's your problem too.
Put a volt meter on the pull in connection (small wire) on the solenoid and measure the voltage when it is just clicking and not cranking. If it is less than the voltage at the battery terminal on the solenoid (big wire from the battery) by much, that's your problem too.
Elite HDF Member
Joined: Sep 2007
Posts: 4,468
Likes: 12
From: Bluffton, South Carolina
Take a jumper and go from the big post on the starter and go to the impulse connection on the starter (make sure you are in neutral). If it starts then you have the "dreaded click". You will need to check for voltage drop throughout the starting wiring. Did you clean the starter and the primary as that is an electrical connection too. Sometimes you need to run a ground from the battery to the starter bolt to ensure a good ground. Hope this helps.
Seasoned HDF Member
Joined: Apr 2011
Posts: 6,185
Likes: 2,134
From: W. Texas
Yeah, it will do that. The Dreaded Click. Most likely not the starter or the solenoid, but the wiring and starter relay. Some of us have installed an auxiliary starter relay that has solved our problems.
Put a volt meter on the pull in connection (small wire) on the solenoid and measure the voltage when it is just clicking and not cranking. If it is less than the voltage at the battery terminal on the solenoid (big wire from the battery) by much, that's your problem too.
Put a volt meter on the pull in connection (small wire) on the solenoid and measure the voltage when it is just clicking and not cranking. If it is less than the voltage at the battery terminal on the solenoid (big wire from the battery) by much, that's your problem too.
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,200
Likes: 3,089
From: NW AR
If the battery voltatg is 11 and you have 10.5 at the solenoid coil when you get The Dreaded Click, I think that should be enough voltage to pull it in and I'd look elsewhere. In my experience, I was getting in the 6 to 8V range, and that's not enough. Next for you to check on that bike would be the voltage on the output side of the solenoid contacts, going to the starter motor. If you have ~10.5V there too (WHEN experiencing The Dreaded Click), I'd say the starter needed attention. If you have << 10.5, the solenoid needs a rebuild/replacement.
You can also try Mia's suggestion of a jumper between the battery cable and the solenoid coil connection. The first time I got The Dreaded Click, I was on the road to Sturgis, so I went back inside the gas station/truck stop and bought a small adjustable wrench, wrapped it with duct tape and kept it handy to short across the solenoid if I had to.
You can also try Mia's suggestion of a jumper between the battery cable and the solenoid coil connection. The first time I got The Dreaded Click, I was on the road to Sturgis, so I went back inside the gas station/truck stop and bought a small adjustable wrench, wrapped it with duct tape and kept it handy to short across the solenoid if I had to.
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5th Gear
Joined: Sep 2011
Posts: 9
Likes: 0
From: Henderson,NV
I tried the aux. relay trick and ,still the same thing,one crank and click. Man I am getting sick of this ,I'm going to tell him to just get a new starter. I've been trying all the cheap stuff first of course.Prolly new batt. cables as well,although they dont show any resistance . .9 ohm . There was a guy on here said he got a starter form Jireh for 130.00 I cant even find em on their site,not for a 95 anyway. Any help ? Also,the pushbutton cover,the owner wants one but it's kinda just a bandaid for a bigger problem huh ?
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