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...

 

Don't you have a picture of the order? Maybe even a fish part break out.

Your battery good with 12.6 and been load tested?

 

I got the battery on the 14th from HD, and took it back Saturday, to have them test it, it was low they just received new batteries that day, So they put it on their machine which drains the voltage and charges it back up they said it was low like 11 volts when I brought it into them, it's also a AGM battery, which I saw somewhere if you charge them you need a AGM type charger, I've always used a battery tender to keep it up, or at least to get a green light. Maybe I should take it to Auto Zone and have them test it, I really don't trust the stealership...

 

I need to check with my mickey mouse new multi-meter from HF, sure isn't my Fluke....:-0

 

12.56 volts at the battery.

 

A regular maintenance charger is fine. It throws 13.5 to 14.5 at a low amp. So yes it takes a full day.

Your still way low for a new battery.

Remember, coming off charger, turn on lights and then off to kill surface charge necessary to charge.

 

I guess I need to buy a charger. The lights come on when you turn the ignition switch .

 

What's battery show charging on charger? 13.5 -14 or so?

12.56 should start it. Just saying that was a bit low for a brand new battery. I mostly have seen 12.7 new. 12.5 on mine produces a start but at that, I start getting a grunt till cylinder clears.

You have something wrong with starter.


What's the battery show when it clicks? Must be over 9.7.

Sorry about grammar and spelling. In a rehab facility.from a broken hip.

 

9 times out of 10 when the bike goes click , click on the starter button , it’s the battery at fault.

 

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I haven't put it on a charger yet, right now with no load on the starter it seems to turn every time. I,ll get a charger today and charge the battery up. And install the jackshaft, that little load made the solenoid just click. I'll try to duplicate the issue and check the voltage.

I'm thinking that it is the starter, since it works with no load, but with the jackshaft installed it is a slight load and the solenoid then fails to work properly.