Starter issues with my 68' sportster ironhead
Tourer
Joined: Mar 2009
Posts: 409
Likes: 126
From: Iowa
Well I took the primary cover off to get a better look at the starter assembly and when I hit the starter button I hear the solenoid click and I can see the be Bendix begin to move towards the ring gear but that's as far as it goes, it barely moves out and doesn't engage, and I hooked up a voltmeter to the battery and it had 12.13 volts with out ignition on, it had 11.79 volts with the ignition on and the voltage dropped down to 10.49 volts on average and got as low a 9.78 volts when I hit the starter button. I'm getting close so what do you guys think now that I have narrowed down the problem?
With your primary cover off, (and the battery cable disconnected from the long stud of the solenoid), can you push the plunger into the solenoid with your finger and cause the bendix to move out far enough to engage the ring gear, or does it bind on something? If nothing's binding, I'd try jumping a battery to the one in the bike to make sure it isn't just a weak battery causing all this.
The primary cover supports the outside end of the starter shaft, so I can see why you woudn't want to run the starter without the primary cover in place. You might break the starter shaft housing if the starter shaft tries to lift up when the starter motor starts turning. Or chew up some non-meshing gear teeth, maybe.
Ironmick, I'm sure you'll be successful in your project. Have fun.
Tourer
Joined: Jan 2011
Posts: 350
Likes: 0
From: Reidsville, NC
Sounds like either A: Battery is weak. or B: Solenoid is on it's way out. You can buy the rebuild kits for the solenoid. I had the same problem on my 80 Ironhead (it has points also) and the contacts inside the solenoid were somewhat melted and the plunger was black. I would pull the solenoid and take it apart, check the contacts and plunger.
When you dismantle the solenoid - It is redious to get it back together. The parts are spring-loaded, and there are square or rectangular connections to line up with square or rectangular openings in the cap. And ensure that the wires are free inside.
Not impossible; difficult is the incorrect word. But tedious is correct. So be prepared. Take your time; Note carefully how things were as you dismantle.
Use spray can electrical contacts cleaner. If the terminals are burned you may be able to simply rotate them to use the good side. I have done this.
A large copper washer in there is a better part than the steel washer in the replacement kits and in the new after market solenoids.
Not impossible; difficult is the incorrect word. But tedious is correct. So be prepared. Take your time; Note carefully how things were as you dismantle.
Use spray can electrical contacts cleaner. If the terminals are burned you may be able to simply rotate them to use the good side. I have done this.
A large copper washer in there is a better part than the steel washer in the replacement kits and in the new after market solenoids.
Tourer
Joined: Jan 2011
Posts: 350
Likes: 0
From: Reidsville, NC
When you dismantle the solenoid - It is redious to get it back together. The parts are spring-loaded, and there are square or rectangular connections to line up with square or rectangular openings in the cap. And ensure that the wires are free inside.
Not impossible; difficult is the incorrect word. But tedious is correct. So be prepared. Take your time; Note carefully how things were as you dismantle.
Use spray can electrical contacts cleaner. If the terminals are burned you may be able to simply rotate them to use the good side. I have done this.
A large copper washer in there is a better part than the steel washer in the replacement kits and in the new after market solenoids.
Not impossible; difficult is the incorrect word. But tedious is correct. So be prepared. Take your time; Note carefully how things were as you dismantle.
Use spray can electrical contacts cleaner. If the terminals are burned you may be able to simply rotate them to use the good side. I have done this.
A large copper washer in there is a better part than the steel washer in the replacement kits and in the new after market solenoids.
Oh and I can move the starter gear out to the ring gear by pushing on the spring it doesn't bind and moves pretty smoothly
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider
Verdad Gallardo
Use your own battery charger to bring the battery up to full charge before bringing it to a shop to be tested. The testing process drains the charge from the battery; if it is not fully charged at the beginning a good battery may test as not good.
Do not let them use a quick charge to charge up your battery. Too many amps in too short of times - OK for a big car battery.
Do you have a liquid filled battery or a maintenance free model? If liquid filled be sure it is topped up before you put it on the charger.
Better still go to Harbor Freight or Princess Auto and buy your own battery tester. On sale days they will be half price - about $40. Nice tool to have at hand.
Do not let them use a quick charge to charge up your battery. Too many amps in too short of times - OK for a big car battery.
Do you have a liquid filled battery or a maintenance free model? If liquid filled be sure it is topped up before you put it on the charger.
Better still go to Harbor Freight or Princess Auto and buy your own battery tester. On sale days they will be half price - about $40. Nice tool to have at hand.
Thread
Thread Starter
Forum
Replies
Last Post
BonzoThunderMtn
Ignition/Tuner/ECM/Fuel Injection
2
Jan 17, 2016 10:17 AM
goliath1
Ignition/Tuner/ECM/Fuel Injection
6
Dec 20, 2012 05:09 PM
