Originally Posted by WP50

That 7.62 does go through the relay. The contacts in it can add to the drop.
If it's in hand give it shot. Are you positive there isn't another relay on the bike that could swap places? ahh never mind ya got a new one use it
Could we talk you into doing the voltage test again after new relay?
Just for curiosity

WP

Originally Posted by mikey95hd

Voltage check 12.60 now at battery, however when checking green wire connected to solenoid it's dropping to 7.62 volts. That's with holding the button after it clicks. I don't think it should be dropping that low.

Originally Posted by mikey95hd

when you turn the ignition on nothing, and when going to off position, the first turn counter clockwise there is a click, that isn't right at a..

Originally Posted by Dan89FLSTC

Another voltage drop test to try:

Read the voltage at the ignition switch connector, the Red/Black wire, while pressing the start button.

The wire must be connected to the ignition switch.

Originally Posted by mikey95hd

Okay

What the hell is going on with my 1995 FXSTC?

Put a rebuild starter, new jackshaft, new stator, new ground cable, new battery. and it seems all I get is a click when trying to start, the starter relay is clicking and the starter solenoid does also. So I took the outer primary off, and removed the compensator, and clutch assembly, and before going any further, I tried it again, still the same. So I pulled the jackshaft assembly, and figured I would try it with just the starter and the coupling that is attached to the motor, guess what the motor turns now. this coupling is installed properly, when you look you see the counter sunk section of the coupling,

So I know that part of the install is right, I haven't worked on the bike in over 2 years and decided it's time to get her up and running again. Also totally forgot how the jackshaft assemble goes back into the bike, mainly the position of the second coupling, I'm sure the jackshaft goes in next and then the shorter side of the coupling goes towards the jackshaft with the other longer side, is where the spring, and pinion gear go, then the pressure washer and washer with tab that locks into the keyway of the shaft and of course the long bolt. I'm pretty sure this is how the assembly goes back together, And I installed it that way the first time, Putting it back together this way the shaft does go out, for the first couple of tries, the third time it just clicked, So now I removed the jackshaft again, and tried it with just the coupling this morning and it works...

I'm thinking maybe the Starter Relay has finally gone south, after all it's 28 years old and ordered a new one on line, Funny thing about all this I bought a Harley so if I ever broke down somewhere in the country, I would be able to find my part at a dealership, WRONG..."THAT PART IS NOW OBSOLUTE"
Also I have not done any of the voltage tests or done any troubleshooting of the starter system yet...bought a multi-meter today at harbor freight..

What i don't understand why does it spin with just the coupling on the starter, and not with the jackshaft, maybe, the coupling is installed wrong after all, I installed the one that came with the starter, which is a rebuild DS starter, and have the one that came out, I saved it, and have the old starter, maybe I'll take it apart and rebuild it again, the solenoid failed on it and I don't know how the brushes look on the motor itself...

Originally Posted by WP50

Dan Do you feel this kinda drop is excessive
Mikey ck Dans post #61
Thanks
WP

Originally Posted by mikey95hd

Well the new relay is a joke, when you turn the ignition on nothing, and when going to off position, the first turn counter clockwise there is a click, that isn't right at all.

Put original relay back in, now same results when holding start switch, drops to 7.58 now and voltage has dropped to 12.58...

Originally Posted by mikey95hd

black red wire at switch reads 11.80 hit switch drops to 9.8


Black red wire is on top by itself

Originally Posted by Dan89FLSTC

Stop...

You are going to guess yourself crazy.

Reinstall the new relay.

After the new relay is installed, read the voltage at the green wire on the solenoid (wire connected), while pressing the start button.