Hello Chaps,

Will try and keep this as short as possible.

So I have just spent the last few weeks rebuilding my 2006 Softail after a complete referb.
It was all going so well, to well I guess.

I got to the stage where all the fluids were in. Pulled the fuel pump fuse in order to turn it over and get oil pressure. Turned on the ignition. Switched it to run, and hit the start button. All good everything worked, oil light went out. Ignition off. Plugged pump fuse back in, turned ignition back on, everything primed, hit the button again - nervously. Nothing. Starter relay clicks away, but nothing.

Now I have done endless checks to try and eliminate things but I am now running out of options.
Here's what I have checked so far:

Changed both the system and starter relays.
Changed and checked all the connections on the circuit breaker.
Checked all the 15amp fuses.
Bleeped out battery to Circuit breaker
Bleeped out battery to Starter connections
Bleeped out both relay connections to their connecting parts through the harness.

All seem good. Now it would seem or should I say sounds like the brand new starter isn't kicking in as it did when I got oil pressure. Can a new soliniod get stuck?
I drained and pulled the primary cover to check the jack shaft, and its not engaged on he clutch ring.
Selected 5th, spun rear wheel, engine turns.

I guess I'm asking if you guys can think of anything that may cause this apart from the starter, before I go though the hassle of having to drain and pull the oil tank to remove the starter, only to find out its not the issue.

Any help or advice is of course greatly appreciated.

Rob

 

Have you checked the most likely cause.... the battery? The battery may have enough juice to turn on lights and prime the fuel pump but it probably doesn't have the cranking amps to turn over the engine.

Have the battery load tested at any auto parts store.

 

Thanks Doc. It's a brand new battery and putting out 12.8v. I will charge it never the less.

 

Starter relay? Double , triple check all your connections...

 

My first thought notgrownup. Changed both. Also bleeped out relay connections to its opposite ends.

 

Run a jumper wire from battery positive to the single green wire terminal connector at the starter and see if the motor turns over. This bypasses your start wiring, switches and relay.

If it then turns over you'll know it's likely an issue with the wiring, switches, relay of your start circuit and not the starter or solenoid.

Using a beep test has its advantages in certain applications but if the starter tests good you should be looking at doing actual resistance, voltage and voltage drop tests to narrow down the problem area.

 

Does it turn over when you pull the fuel pump fuse out again?

 

Thanks J_bee, I will attempt to use the jumper wire today. If I can get that damn connection out that is. Its not the easiest to get to as you know! After that I was going to try and get the solenoid cover off and see if it was stuck. Really don't want to pull that oil tank again. Annoying as the weather here is nice today and I should be out riding.

 

Good thinking. I will try. Thanks

 

OK so been fumbling and this is what I have found.

I forgot to mention in earlier posts that this is a brand new starter.

Starter wouldn't jump when I jumped from positive post to the green wire connection. Tried positive terminal on battery too.
I'm getting good voltage at the end of the green wire when I turn it over, and I'm getting 12v between the two connection points on the solenoid when bike is off.
I also measured between the green wire and the neg on the battery. Got 11.3v with the bike on and 12.9v when I hit the run switch.

Managed to pop the cover on the solenoid. Pushed the plunger in with the bike on and got nothing.

Rechecked all my grounds and now scouring the schematics in my manual!!!

Any more suggestions??