Starter pinion not always engaging into ring gear

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Nov 24, 2021 | 01:04 PM

#21

Captnjoe

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Joined: Dec 2020

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From: FL

OK here we go after going through this with a fine tooth comb I noticed that depending on how or what angle I pushed the starter button seem to effect it so before adding another relay I decided to look closer at the starter/stop switches of course I had to actually take the switches apart to examine them witch meant replacing them anyway but anyway after taking them apart I found both the starter rocker switch and the stop rocker switch were both very badly corroded and I mean very badly. Now after replacing them it's starting properly again keeping my fingers crossed it keeps starting if not than I'll try adding the second relay. I personally have never seen those switches corrode like that but guess there is always a first time. I can't help but wonder what caused them to do that.

Dec 11, 2021 | 10:30 AM

#22

Captnjoe

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From: FL

OK after all the bs I've been through with this issue quite by accident I stumbled across the problem I found that if I turned of the extra marker lights I had no problem starting the bike when they were on the starter wouldn't engage a bad connection in those lights was putting a major strain on the battery drawing way to much current after fixing that connection the starter problem went away. Seems like it's always something simple and stupid that cause the biggest problems. The moral to the story is its not always the obvious.

Dec 11, 2021 | 11:07 AM

#23

pgreer

Stellar HDF Member

Joined: Aug 2020

Posts: 3,185

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From: College Station, TX

Glad you found the problem and let us know.

Paul

Dec 14, 2021 | 01:26 PM

#24

CarlosGGodfrog

Road Captain

Joined: Apr 2015

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From: Menomonee Falls, Wi

Convert the lights to LED. Verrrry low current draw.

Dec 19, 2021 | 11:39 AM

#25

Captnjoe

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Joined: Dec 2020

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From: FL

As many of you know I've been dealing with this issue for over 3 months now lack of power getting to the starter has been the problem all along. Ounce again I thought it was fixed it worked great for a couple days than started the same **** up not getting power to started. Well today I was back on the internet trying to get more ideas about it and stumbled across this describing the exact issue I'm having.

1995 HARLEY DAVIDSON Flht Recalls

Recall Description
VEHICLE DESCRIPTION: FL TOURING MOTORCYCLES. A LOSS OF ELECTRICAL POWER THROUGH THE IGNITION SWITCH CAN OCCUR DUE TO EXCESSIVE CURRENT AND OTHER FACTORS.
Possible Effects
THIS CONDITION CAN CAUSE THE ENGINE TO FAIL TO START, OPERATE ERRATICALLY, OR STALL.
Action
DEALERS WILL REPLACE THE IGNITION SWITCH/CIRCUIT BREAKER AND INSTALL A RELAY KIT.
Notes
OWNER NOTIFICATION BEGAN JULY 20, 1998.OWNERS WHO TAKE THEIR MOTORCYCLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Recall Manufacture Dates
1993-04-12 - 1998-06-29
Vehicles Affected
my bike is listed among the ones affected couldn't get it to copy the rest of the article so I'm supplying the link for anyone else who may have a similar issue. Harley service department is closed today tomorrow I will be on the phone to them .

https://howtune.com/recalls/harley-davidson/flht/1995/

Last edited by Captnjoe; Dec 19, 2021 at 11:42 AM.

Dec 19, 2021 | 12:04 PM

#26

hattitude

Seasoned HDF Member

Joined: Sep 2008

Posts: 14,166

Likes: 11,263

From: San Diego, CA

Quote:

Originally Posted by Captnjoe

1995 HARLEY DAVIDSON Flht Recalls

Recall Description
VEHICLE DESCRIPTION: FL TOURING MOTORCYCLES. A LOSS OF ELECTRICAL POWER THROUGH THE IGNITION SWITCH CAN OCCUR DUE TO EXCESSIVE CURRENT AND OTHER FACTORS.
Possible Effects
THIS CONDITION CAN CAUSE THE ENGINE TO FAIL TO START, OPERATE ERRATICALLY, OR STALL.
Action
DEALERS WILL REPLACE THE IGNITION SWITCH/CIRCUIT BREAKER AND INSTALL A RELAY KIT.
Notes
OWNER NOTIFICATION BEGAN JULY 20, 1998.OWNERS WHO TAKE THEIR MOTORCYCLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Recall Manufacture Dates
1993-04-12 - 1998-06-29
Vehicles Affected
my bike is listed among the ones affected couldn't get it to copy the rest of the article so I'm supplying the link for anyone else who may have a similar issue. Harley service department is closed today tomorrow I will be on the phone to them .

https://howtune.com/recalls/harley-davidson/flht/1995/

Good find.....

Let us know if this fixes your problem once and for all....!

Good luck with the repair...

Dec 28, 2021 | 01:55 PM

#27

Captnjoe

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Joined: Dec 2020

Posts: 28

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From: FL

Can you believe this **** all of this just to put a new ignition switch in talk about being frustrated! I need a drink maybe more than one come to think of it! LOL

Dec 28, 2021 | 07:32 PM

#28

hattitude

Seasoned HDF Member

Joined: Sep 2008

Posts: 14,166

Likes: 11,263

From: San Diego, CA

Wow.... that's a crazy amount of work to replace an ignition switch....

I'd hate to show you a pic from when I replaced the ignition switch on my 2016 Ultra Classic.... it was child's play in comparison...

But when it needs to be done..... slow and steady wins the race... !

Looks like you're doing a good job of it....