My buddy has a 2007 Deluxe, ran with no issues until recently. Now the starter makes a wierd noise before the bike starts running. He's even had the bike start up by just turning the On/Off switch to On without hitting the Run button. Anyone seen this before?

 

still under warantee take it back to dealer i know the starter bendix make some noise normally but he might have a wire issue

 

Never heard of that one. Sounds like something is grounding out.

 

Tell him to check the voltage at the Green wire that runs to the Starter Solenoid. It should only have 12vdc when the starter switch is pressed (with the Run switch in the Run position). If it has voltage all the time, then replace the Starter Relay.

 

Apparently there was a service bulletin issued regarding starter issues in 2007/2008 bikes, you can read about it in this thread:

https://www.hdforums.com/forum/touri...ter-issue.html

 

Barring any problems already mentioned, try the following from my school notes to determine where the fault lies using multimeter and thin-bladed probes and about 10 minutes time to read voltage drops:

STARTER TESTS

*All tests performed with ignition disabled and run/stop switch to “run”: pull igntion relay from fuse box or remove S/Ps and place in wires, then tape together where will not touch engine and fire cylinder. Must have fully (100%) charge in battery to accomplish!
**Tests #1 through 4 performed with starter relay installed & engine cranking when says "depress start switch": readings taken at relay pin locations.

PRE-TEST: 1. BATTERY VOLTAGE WITH KEY ON___________VDC (LOADED BATTERY VOLTAGE) DVOM LEADS TO BATTERY TERMINALS RECORD VALUE

1. 86 Terminal checking starter switch operation: red multimeter lead to battery +, black to relay pin #86 key on/depress start switch should read 1VDC, 2.0VDC for FLT max.

2. 50 Terminal checking starter relay: red multimeter lead to battery +, black to starter “50” terminal (green wire) key on/depress start switch should read 1VDC max.

3. Motor Terminal checking starter solenoid: red multimeter lead to battery +, black to starter terminal “C” (short silver wire) key on/depress starter switch should read 1VDC max.

4. Starter Motor Ground: red multimeter lead to starter mount bolt, black to battery –
key on/depress start switch should read zero volts

*The following tests are performed with starter relay out and readings taken at
pin-numbered fuse box relay location. Engine will not crank.

5. Power to Relay @ Terminal 86: red multimeter lead to fuse box pin location #86, black to battery – key on/depress starter switch should read battery voltage

6. Power to Relay @ Terminal 30: red multimeter lead to fuse box pin location #30, black lead to battery – key on/depress starter switch should read battery voltage.

7. Starter Relay Ground in OHMS: red multimeter lead to pin # 85, black to battery –
key OFF depress start switch should read 300K OHMS with TSSM equipped bikes or “continuity” for all others (TSM)

*Starter relay back in fuse box.

8. Power to Terminal 50 (Green Wire): read multimeter lead to relay terminal 50 (green wire), black to battery - key on/depress starter switch should read battery voltage