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Just read this post, let me see if I got this right...
You had a grinding starter, causing some damage to the ring gear.
You have:
Installed a new starter
Installed new starter wires
Installed new ring gear
Verified that both ring gear & starter are installed/seated properly
AND you still have the problem...?
If all the parts/pieces to the starter circuit are installed properly, and assuming all the new parts/pieces are in good working order, then I would suspect the power source to the starter...
I don't see mention of load testing and/or replacing your battery. You also didn't mention checking your main ground wires, or was that included with "new starter wires"?...
I'm just throwing those out there because I didn't see them mentioned...
Trouble shooting can be very frustrating... especially electrical...
Not being present for troubleshooting a mystery like this, makes it hard to offer good suggestions.. because there are so many little things to look at and check out.
When I run into a wall like this, I start at the beginning and follow from the source to the end, including a double check that I have the right parts/pieces for my application.... But first I would take a break and a deep breath.. Mysteries like these tend to raise my blood pressure and negatively affect my thinking/reasoning...
In this case, I would be starting with the 12 volt power source, following it to the starter. Then check the functioning of the starter (probably bench test it), the engagement of the ring gear, and then finally the spinning of the engine by the ring gear (clutch/comp/chain)...
The fact is that it worked fine before, so something along that path isn't working right or fitting correctly....
Keep at it, good luck, I'm sure you will find the problem... Let us know what you eventually find..
Your correct in your assumption I've replaced the battery and all new leads to battery just the other day I even replaced the battery leads again in desperation and went from a 4ga to a 2 ga. The rest of what you offered I have checked and double checked and stared at until I'm blind even though the starter is new I did take it out again and benched checked it. I'm believing now it has to be a power issue probably a grounding issue at least that's what I'm focusing on at present. In actuality at this point I'm just taking shots in the dark. Thanks for your input.
Hi I ran a 4ga ground wire yesterday from the lower front inner primary bolt to the frame the first time I hit the starter it didn't engage properly the second time it did so I'm in testing mode now very few hours I hit the starter and so far it's engaged every time checked it 6 times yesterday that's definitely progress the way it's been acting is it would never engage after sitting overnight so when I got up and tried it this am much to my surprise it engaged I intend to keep this up for the next day or two before I completely put the bike back together and put out back in the primary just in case. Understand I've been battling this for a good three months now so before I waste time putting all back to again I want to be responsible sure it won't have to come down again.LOL It's foiled me a couple of times now. I'll let you know what happens.
I agree with Bingee that the starter switch circuit may be the issue, the coils in the solenoid are not getting sufficient current to pull the plunger into position and hold it there.
The starter relay gets its current by way of a very convoluted path, and a little corrosion at each point adds up.
Clean the terminal at the solenoid (the small wire from the relay).
Clean all terminals on relay and relay connector.
Clean the terminals in connector 3, between the main harness and the interconnect harness (it has 3 wires).
But you could also consider adding a second relay, which will give the solenoid a nice fat power supply, this is done by adding a second Bosch type relay which will get its power directly from the main breaker without passing through any connector points.
Second starter relay wiring:
Last edited by Dan89FLSTC; Nov 13, 2021 at 06:18 AM.
Have you tried manually pushing the solenoid plunger to see if the starter and ring gear engages properly? Many people will add the push button on the solenoid so they can start the engine if the solenoid fails. That eliminates much of the wiring, relay and switch, at least the wire and power from the relay to the solenoid. You still need a good battery, cables and ground.
As has been mentioned, go old school and simplify the starting process as much as possible and work out from there. Good luck.
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