Electrical issue 04xl1200r
Thread Starter
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4th Gear
Joined: May 2020
Posts: 8
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From: Hawaii
Electrical issue 04xl1200r
Hi everyone, long time listener, first time caller. My sporty has been down for a couple months and I'm at my wit's end with it. Recently replaced my stator, starter, and flywheel, and after putting everything back together, I've encountered a weird issue. When I attempt to reconnect the battery, the positive lead arcs like hell and instantly starts melting the terminal. Asking around people have told me I have a short, or my battery is bad. I've replaced with a new battery to no avail, and have yet to find a the short. It should be noted that this only happens when connecting the lead from the starter, the other line with the maxi fuse works fine. Due to the current lockdown I am also unable to take it to a shop, they're all closed around here and have a 6+ month backlog of repairs. Any help appreciated. Thanks!
Thread Starter
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4th Gear
Joined: May 2020
Posts: 8
Likes: 0
From: Hawaii
Old starter was done for, and chewed up the (at a loss for the name right now, the wheel it spins to turn the motor over) so I replaced both. Did the stator while I was in the primary as it was pretty black.
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4th Gear
Joined: May 2020
Posts: 8
Likes: 0
From: Hawaii
How could a seized motor create this issue? I had thought the solenoid could be grounding, but no idea what to do about that short of a new starter that I can't really afford.
Seasoned HDF Member
Joined: Apr 2010
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From: Long Island, New York
Start with the basics. You have a short, the battery cable arcing all over the place tells you that, so you have a problem.
The mostly likely culprit is you mixed up some wires during the installation. No worries, it happens.
Go back wire by wire and check all of your connections VS your Factory Service Manual. Check that they are all clean with good connections. Check all the wires for exposed copper, fraying or general wire disrepair.
If all is at it should be and all the connections are clean and in order then we need to talk some more. Good luck.
The mostly likely culprit is you mixed up some wires during the installation. No worries, it happens.
Go back wire by wire and check all of your connections VS your Factory Service Manual. Check that they are all clean with good connections. Check all the wires for exposed copper, fraying or general wire disrepair.
If all is at it should be and all the connections are clean and in order then we need to talk some more. Good luck.
Road Master
Joined: Jun 2013
Posts: 1,239
Likes: 1,171
From: St. Catharines, Ontario
I mean the starter motor. Electric motors that can't turn are very low ohms almost a short and draw very high amps like you saw when you touched the lead to the terminal.
. Good advice from Architect, I kinda assumed you double and triple checked the wiring.
. Good advice from Architect, I kinda assumed you double and triple checked the wiring.
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Road Master
Joined: Feb 2018
Posts: 911
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From: west coast
For test purposes ONLY you could wire a small 12V bulb temporarily between the battery and the cable...so long as the short is present it will glow at full brightness but will limit current i.e. a 12W bulb would only pass about 1 amp max. When the short is gone the bulb will go out, or at least become very dim... Do not try to turn the bike on or start it with the bulb connected, it is only used to find a dead short like you evidently have.
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Joe Kucinski
Seasoned HDF Member
Joined: May 2008
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From: South Carolina
If there is a short that is drawing enough amperage that it makes the battery terminal hot, it must be between the battery and the starter.
Only the battery cable could carry enough amperage to do that, if it were one of the smaller wires, the small wire would be toast, or the main breaker would trip.
There are two big terminals on the starter solenoid, measure the resistance between them. It should be infinity.
Just a safety note here, always connect the positive terminal before connecting the negative terminal.
Only the battery cable could carry enough amperage to do that, if it were one of the smaller wires, the small wire would be toast, or the main breaker would trip.
There are two big terminals on the starter solenoid, measure the resistance between them. It should be infinity.
Just a safety note here, always connect the positive terminal before connecting the negative terminal.
Last edited by Dan89FLSTC; May 5, 2020 at 02:17 PM.
Seasoned HDF Member
Joined: Sep 2017
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From: England
Just a safety note here, always connect the positive terminal before connecting the negative terminal.
