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I have an '04 FXDL carb bike, 8300 miles. 95" kit with KB pistons and gear drive cams. About 1000 miles after the install (3500 miles)of the big bore kit, it would not start after riding it for a while, just click. I could push start it, thanks to good bros. Rebuilt the solenoid and all was good for another 4500 miles. Now she is doing the same thing. Any ideas as to what is causing this?
First have your battery tested to see if it is weak and check all of your connections (don't forget the ground strap)and voltage regulator to make sure IF the battery is ok that there is no othervoltage leak or shorton the system. If all that checks out I would takelook at the solenoid contacts to see if there is any signs of over heating. If that is ok..take the starter motor and have it tested with the solenoid connected and disconnected. Make sure you inspect and test all the wiring with a meter. If all that checks out next would be the start switch but I doubt if that is bad. Also, make a mental note when removing the starter to see if itpulls right out or if it seems to be binding in any way. Double check your wiring against the service manual. But you may have something as simple as a loose or dirty contact.
Oh yeah almost forgot......test your starter relay as well. Make sure it is plugged in all the way and the contacts are clean. Usually they just crap out but I have seen on go intermittent and make you crazy. Note: the relay is not repairable.
Solenoid contacts have alot ofblack build up. Cleaned and still just clicks. Getting another rebuild kit soon. All the rest of the electrical system check good.
I Agree, my 00' FXST has a 10:1 build with 40deg closing on the intake, it has around 190 cold cranking comp, I use the comp releases all the time, probably could get away not using them but they are cheap and EASY to replace vs a starter.
They really reduce the strain on the starter and battery especially on freqent hot restarts. Chewy
She's running again. I pulled the battery, checked for the starter being in a bind (it wasn't), and then cleaned every connection before putting her back together.
I think it was just a bad connection. I did order a set of compression releases. The SE heads are already tapped for them. Just have to remove the plug.
Thanks for all the help and input.
You were saying to test the starter relay, how do you test it? I have a 2000 FXD and I go through 2 to 3 relays per summer, when I install a new one it fires right up. Iâm wondering WTF is causing them to go bad. HD said itâs normal for them to go bad but I donât believe that often.
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