Starter wont engauge
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Intermediate
Joined: Jun 2016
Posts: 26
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From: memphis
Starter wont engauge
I replaced the primary gasket on my 76 flh. afterwards the the bike acted as if the battery was weak and barely turned over, charged it overnight and didnt solve the problem. Ordered a new battery. charged it for 48 hours like it said. same problem. I rewired this bike back in the summer and have had No issues. Took the starter off and tested it. Its good. Pulled the primary back off thinking something might be in a bind.found nothing. Put the primary back on only snuggling it to try it again.button wont start the bike but I jumped the solenoid and it fired right up. I did notice that the primary had the chrome cover on the solenoid shoved over to the point you cant get a socket on to remove the solenoid. About to pull my hair out. could it be the relay? And if so why?
Tourer
Joined: Aug 2015
Posts: 433
Likes: 67
From: NOR CAL
the relay can be bypassed with a wrench/screwdriver across the solenoid like hot wiring a older car check electrical connections
my relay ground would be a problem but normally the start push button won't work if its the relay thats why i suggested bypassing/hotwiring the solenoid that will bypass the relay
my relay ground would be a problem but normally the start push button won't work if its the relay thats why i suggested bypassing/hotwiring the solenoid that will bypass the relay
Last edited by TOFTS; Nov 7, 2016 at 12:55 AM. Reason: relay ground
Seasoned HDF Member
Joined: Oct 2005
Posts: 7,499
Likes: 3,717
From: Santa Klaus County, Cali
"button won't start the bike" as in when you push the starter button, there is nothing? If so that could indicate a bad connection in your start button wiring. The start button has 2 wires one crosssing to the kill switch and the second connecting to the #3 position on your relay. Have you checked to make sure all the connections are tight? Might be time to pull the switch housing and make sure there are no pinched or broken wires.
And I know this is stupid of me to ask but....is your kill switch engaged which would make the start button dead.
And I know this is stupid of me to ask but....is your kill switch engaged which would make the start button dead.
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Intermediate
Joined: Jun 2016
Posts: 26
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From: memphis
All of the wiring is cool.I have riding this bike alot since I rewired it with no problems. cranked everyday..this problem started when I put the primary cover back on. ive had three shovels, never have I seen the primary cover actually pressed against the solenoid. This bike has true dual pipes and that goofy heat plate covering the pipe and solenoid. First I thought maybe that heat shield was shorting something. pulled it off and it was the same.that chrome cover around the solenoid being pushed back by the primary cover is the only thing I could see that could ccase any of this. Could it be something binding could have blown the relay. Something was shorted because when I put the new battery on it sparked like ****.
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Seasoned HDF Member
Joined: Oct 2005
Posts: 7,499
Likes: 3,717
From: Santa Klaus County, Cali
HD used a rubber boot for the solenoid cover; chrome one would be aftermarket. With the chrome cover off does it fire with the e-start button?
And can you post a pic of your primary cover with your described interference?
In 1976 HD was still using a "fusible" wire between the relay and the +-side of the battery. I think in 78 they replaced that with a circuit breaker. You said you re-wired the bike. Did you update that or do you still have the "fusible wire" in place? If so and that wire shorted, that wire could be the cause of your problems.
And can you post a pic of your primary cover with your described interference?
In 1976 HD was still using a "fusible" wire between the relay and the +-side of the battery. I think in 78 they replaced that with a circuit breaker. You said you re-wired the bike. Did you update that or do you still have the "fusible wire" in place? If so and that wire shorted, that wire could be the cause of your problems.
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Cruiser
Joined: Apr 2011
Posts: 188
Likes: 17
From: SE Pa.
All of the wiring is cool.I have riding this bike alot since I rewired it with no problems. cranked everyday..this problem started when I put the primary cover back on. ive had three shovels, never have I seen the primary cover actually pressed against the solenoid. This bike has true dual pipes and that goofy heat plate covering the pipe and solenoid. First I thought maybe that heat shield was shorting something. pulled it off and it was the same.that chrome cover around the solenoid being pushed back by the primary cover is the only thing I could see that could ccase any of this. Could it be something binding could have blown the relay. Something was shorted because when I put the new battery on it sparked like ****.
When you pulled your primary cover off, you may have inadvertently slid the starter shaft (pt# 31482-70) slightly outward, preventing the starter shaft to properly engage w/the starter gear (pt# 31485-65), preventing the bendix gear (starter drive gear unit pt# 31443-65A) to engage properly with the clutch hub, causing your starter to labor.
Disconnect your battery, remove the primary cover, twist back and forth the starter shaft while pushing it inward. If you feel the starter shaft move back inward approx. 1/4", this might solve your problem.
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