Strange electrical problem
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Road Warrior
Joined: Aug 2006
Posts: 1,327
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From: S.E.PA
Sounds like the battery is not up to snuff ...too much voltage drop. If the voltage goes down,amperage goes up...that's why the terminals are hot. Are the battery cables big enough for the starter? Tried jumping it off with a bigger battery? If you get that much drop with a car battery, either the cables are too small...the solenoid is burnt...your have a bad connection in the cables or the starter is bad. I just read your post again....250 amps???? A 1.4k starter should draw around 116. Still say I would look closely at the cables...if you can't find it there the starter is toast. Good luck
Tom,
Yeah the battery, I had trouble with this Odyssey from the get go the shelf life or standing voltage what they are known for was always weak losing say from 12.85 to 12.70 in say 3 weeks when my HD glass mat battery loss over the non riding season 12.85 to spring 12.80 and I was in touch w/Odyssey about that, my cables are 4 Ga Terry cables, stock were 6 Ga I believe, solenoid in a new or NOS OEM HD solenoid just installed this spring, I have a new starter relay, ground connections were checked.
I know 245 AMPs sounds like a lot, its been doing that since the first time I check it 3 years back, here is my take on that, 1.4 kW starter is twice the draw as the stock HD unit of .7 or .8kW a electrical book I have on motorcycles states 1000cc to 2000cc can draw up to 200 AMPS, I even told All ***** person what it was at 224 AMPs when I first tested it, he said sounds about right, but I see your point my best riding buddy an auto wrench of 20+ years says the same thing as you its too high ?
I am waiting for a friend to come over with a battery load tester.
One thing when I was on my second test (AMP test) like I said no more than 2x at 5 seconds long each, but in the last one it really started to drag, tiny moment at the end of the first test, but really drag and stopped turning in the second, I didnt hear the solenoid drop out thats when I felt the terminals on it was real HOT, so I disconnect the battery fast.
Could that be because this new solenoid is bad ? or because the battery just ran out of power causing it to stick ?
Thanks for the come back
cj
Seasoned HDF Member
Joined: Nov 2009
Posts: 15,705
Likes: 22,718
From: Farmington ,MS
Pull the solenoid in manually,and check for resistance across the terminals. It could be that the bendix gear is in a bind when it pulls in. I know the voltage drop is too much, and 99% sure the amp draw is too much...it is drawing 3000 watts...it is rated @1400
Road Warrior
Joined: Aug 2008
Posts: 1,306
Likes: 864
From: Sheboygan, WI
i'd say it's because the battery voltage dropped out, causing the solenoid contacts to weld together. Explains why the solenoid bolts got so hot too.
Last edited by d_slat; May 30, 2010 at 05:14 PM.
Thread Starter
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Road Warrior
Joined: Aug 2006
Posts: 1,327
Likes: 0
From: S.E.PA
Pull the solenoid in manually,and check for resistance across the terminals. It could be that the bendix gear is in a bind when it pulls in.
How do I pull the solenoid in manually please dont tell me to spin the rear tire : - ))
The bendix was replace two years ago
I know the voltage drop is too much, and 99% sure the amp draw is too much...it is drawing 3000 watts...it is rated @1400
Its a fluke meter and fluke amp clamp and like I said two sources one up to 200 amps the other one was All ***** starters themselves, I know the HD shop manual states when reading a amp reading of 100 amps inspect the starter I also know that my owners manual told me and up to a friends 84 FX to inflate tires at the wrong psi readings, it was wrong in those manuals for 4 years who knows how far back, I never just put in 24 lbs in the front , 26 in the rear, not that I was smarter than HD, it just didnt sound right to me maybe it was because I am a bigger guy who knows but I never used their figures as a base, also who the hell ever used the manual and put 4 qts of oil in their bike ? maybe a good 3.5 yeah but 4 qts ? my buddy did until he caught on when the oil dip stick landed in his front yard : - )))
The correct tire pressure at last made it in the FX 78 to 84 shop manual, 30 lbs in front 32lbs in rear but wasnt corrected until the 84 shop manual, how many people you think followed those under stated air pressures in their manuals ?
Tom,
that is why I dont believe in shop manuals 100% of the time.
Thanks for trying to help me hear, I am getting tired of this in a bigger hurry : - )))
cj
Thread Starter
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Road Warrior
Joined: Aug 2006
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From: S.E.PA
d,
Buddy I am wishing for that fix so damn bad its not funny, I am on pins waiting for this guy to stop by and load test my battery, but I did tell him I guess I may have given him a wrong lead, yeah making sure its fully charge for you be later this afternoon, now I remember I did say hay if it takes til tomorrow just come then !!! : - )))
I want you to be right !!!!!
Thanks for telling me the thing I wanted to hear, yeah I also know we can be both pissing in the wind : - )))))) thats how Harleys are : - )))))
Take care
cj
Seasoned HDF Member
Joined: Nov 2009
Posts: 15,705
Likes: 22,718
From: Farmington ,MS
Take the solenoid off, stick your finger inside and push the little button,then you can check the resistance with your fluke. There are several things that can be wrong with the bendix ...it has to be properly shimmed with brass washers that go on the outer primary side. If you have aftermarket primary cases or aftermarket clutch basket the gear may not be aligning correctly...it is actually a pretty crappy system and EVERYTHING has to be perfect for it to work for very long.
Stage II
Joined: May 2010
Posts: 2
Likes: 0
thanks for that i herd you can make a diferent tipe by useing a spring and leaver in the soloniod stop and a start button
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Thread Starter
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Road Warrior
Joined: Aug 2006
Posts: 1,327
Likes: 0
From: S.E.PA
Take the solenoid off, stick your finger inside and push the little button,then you can check the resistance with your fluke. There are several things that can be wrong with the bendix ...it has to be properly shimmed with brass washers that go on the outer primary side. If you have aftermarket primary cases or aftermarket clutch basket the gear may not be aligning correctly...it is actually a pretty crappy system and EVERYTHING has to be perfect for it to work for very long.
Ok on the solenoid
As for the shimming with brass washers other than the one in the outer primary the starter shaft I know I replaced that a last year paying I think it was $14 or $17 bucks for a brass washer !
For the bendix gear I didnt do it I was leaving for vacation a few years back, just didnt have the time so I let a local m/c independent do it, they work on HD but as you know doesnt mean that much : - ))
I dont have the stock inter-primary cover when I was installing my new Rivera pro clutch, if I was going to remove the clutch/basket well have the inter-primary chromed thats when it was discovered a hair-line crack in it, so got a Cal Products inter-primary, but everything bolted up to it meaning stock basket and stock starter motor at the time, the starter shaft and gear housing went back as it came out everything worked but that was back in mid 02
As you seen I am really hoping its the battery, yeah base most on hoping : - )) and a few things going on, time is getting close to ride up to Lake George NY leaving in 8 days !!
Thanks again I will try it,
cj
Seasoned HDF Member
Joined: Nov 2009
Posts: 15,705
Likes: 22,718
From: Farmington ,MS
This could be your problem. You have to check the distance the bendix gear comes out into ring gear...and shim it with those $14 washers. I have 2 thick ones on mine to get it correct. Might try experimenting with the plugs out to see what is binding...Something is wrong is why you are pulling so many amps. I hope you can find it before your trip.