Beyond Frustration
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Joined: Jul 2011
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From: South Korea
Beyond Frustration
1987 Sportster. Bought it from a co-worker 1 ˝ years ago, and I’ve been working on it since then. It will not go. I live in South Korea, so please don’t say “mechanic” – that’s not an option.
When I got it, it went for just a few miles at a time before the engine overheated and it stalled. After a few months I figured out that the problem was the Shorty E carb, which was way too big for an 883. The piston heads had turned to carbon that would not come off, so I did the 1200 conversion last winter. The scoot stayed inside for the winter. Since then it won’t start. There is a heavy “click” from the solenoid pushing the pinion gear out, but the starter motor does not crank at all. I replaced the starter motor, the battery, and everything in between – main wiring harness, fuses, relay, ignition barrel, ground cables…everything. I did it very carefully over a few months. I’m sure I didn’t do anything wrong or miss a ground connection (I didn't mess with any of these when I did the conversion anyway). Nothing made any difference – solenoid click all the way.
I bench tested the first starter twice. The first time it worked just as it should, so I replaced the wiring and stuff. Second time it did not crank, so I replaced both it and the battery. I was very careful with the 1200 conversion – I don’t think I missed anything there. The pistons moved fine in the cylinders when I had finished, and they still do.
I guess I must be missing something, but it’s not anything I can find from the manual or internet. Any useful ideas?
When I got it, it went for just a few miles at a time before the engine overheated and it stalled. After a few months I figured out that the problem was the Shorty E carb, which was way too big for an 883. The piston heads had turned to carbon that would not come off, so I did the 1200 conversion last winter. The scoot stayed inside for the winter. Since then it won’t start. There is a heavy “click” from the solenoid pushing the pinion gear out, but the starter motor does not crank at all. I replaced the starter motor, the battery, and everything in between – main wiring harness, fuses, relay, ignition barrel, ground cables…everything. I did it very carefully over a few months. I’m sure I didn’t do anything wrong or miss a ground connection (I didn't mess with any of these when I did the conversion anyway). Nothing made any difference – solenoid click all the way.
I bench tested the first starter twice. The first time it worked just as it should, so I replaced the wiring and stuff. Second time it did not crank, so I replaced both it and the battery. I was very careful with the 1200 conversion – I don’t think I missed anything there. The pistons moved fine in the cylinders when I had finished, and they still do.
I guess I must be missing something, but it’s not anything I can find from the manual or internet. Any useful ideas?
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