Ongoing saga of the "starter" problem

[gtrman66]

Well, so far it still starts.

Quick history. '95 EVO FLHT, 80" bored 0.010" over with SE Heads.
This is a recurring problem over the last 8 years or so.

This year I have had the starter rebuilt, replaced the stator rotor and 2 voltage regulators. The battery is sealed and new. New Volt Meter.

Everything was perfect for about 3 weeks. Then it started happening again.

First thing in the morning, it will sometimes "click" on the first punch of the starter and then all works fine. This lasted about 2 weeks.

Last Thursday (last time I rode) it started fine, but died when I failed to keep the throttle cracked enough until it warmed up. I got nothing but, "click" when I tried to restart. A trick I learned a while back is to put it in gear, rock it a couple times and try again... starts right up.

This morning I pushed the button and only got a "click". Put it in gear, rocked it and... no problem.

The rest of the day it starts like a champ.

Now I know from experience, the problem will only get worse and worse until I start replacing stuff again. Everytime I replace ______(fill in the blank) it seems to fix it, only to have the problem return. The only things in the chain left are the relay (replaced a couple years ago), the switch (never replaced) and the actual wiring, right? Am I missing anything?

Any insight is greatly appreciated.

[Badassbrutus]

sounds like its binding is it shimed properly??

[SCHMIDTYS]

Has your bike gotten the recall ignition switch update ? It was campaign # 0091 , HD service bulletin M-1071 . It was a safety campaign so letters went out to all original owners . I think it covered touring models from 1994 - 1998 . The kit had a new ignition switch plus a wire harness that plugs in between the switch and the main harness and has a relay in it . You'll see it if you have the fairing off or you can call any HD shop with your serial number and they can look it up to see if it's been done .

[gtrman66]

I seem to recall (pun intended) that I had the recall performed, but I'll check. I have been thinking that I might need to clean the switch and connectors.

Shims? I never used any.

It bugs me that it works perfect for 3 weeks and then slowly regresses. The other thing that bothers me is it is only a "first thing in the morning" problem (for now). If history repeats itself, the problem will start getting worse until I am push starting a 900 pound bike to get home one night.

[Dave63]

Originally Posted by gtrman66

I seem to recall (pun intended) that I had the recall performed, but I'll check. I have been thinking that I might need to clean the switch and connectors.

Shims? I never used any.

It bugs me that it works perfect for 3 weeks and then slowly regresses. The other thing that bothers me is it is only a "first thing in the morning" problem (for now). If history repeats itself, the problem will start getting worse until I am push starting a 900 pound bike to get home one night.

As much as it sounds like a diminishing voltage issue, it doesn't make sense that it's a switch, if replacing the starter makes it all better, but then degrades back to the original problem again in a few months.

What I would do, is check all grounds from the battery to the frame, and if necessary, run another ground strap from a starter mounting bolt to the frame, if not directly to the frame ground strap from the battery.

The other thing, is the condition of the positive battery strap. Are the ends tight and no fractured copper inside the housing?

It almost sounds like something is creating a draw on the starter and causing the issue, more then the button......IMHO.

[gtrman66]

I'm thinking, between the age of the bike and the miles (100k+) replacing the 2 main battery cables (+ to starter and - to frame) might be cheap insurance.

This problem has cycled through several times over the last 8 years and everytime I thought I "fixed" it, only to have it return.

BTW, the Voltmeter is reading a healthy charge and the battery maintains a 13+ charge even after sitting a few days.

[SCHMIDTYS]

I've got something for you to look for especially since you say the starter was rebuilt .
First disconnect the battery then take the triangular cover off the starter pull in coil then take the contact plunger out and the plunger spring . Now ... look into the spring hole with a flash light , is it empty ? There's supposed to be a ball bearing in there ! If there is no ball bearing then look in your old starter clutch output shaft to see if it's still in there . The HD clutch " kit " they sell now is the clutch and output shaft and spring ... no ball .
If you don't see the ball then let us know and I'll tell you how to get one in there without tearing the whole mess apart .

[gtrman66]

The shop I had it done at has a really good reputation. They do a lot of Harley Starters. If it didn't have that ball (I know which one you are talking about), it wouldn't work at all, would it? Like I said this problem has been on again/off agin for 8 years with various starters, stators, batteries...

This morning I got the "click", pressed the starter button about 5 times before it connected and started up nice and strong. I do not have the problem when I go to lunch or go home at night, just first thing in the morning (for now). Eventually, I expect the problem will creep into the later hours. I just do not want to repeat the cycle of replacing every component, only to have it "fixed" for 3 weeks and the cycle to start again.

I'm going to look around for some new battery cables next. This weekend, I want to open up the switch and clean it. I remember that I did have the recall performed while I was living in Brownsville, TX.

[Badassbrutus]

you know I always had problems with rebuilt starters.can ya buy a Spke or Tech Cycle high output starter and just upgrade it?

[scol]

Is it posible to get your hands on a good used starter from another bike and see what happens, if it works OK then your rebuilds are no good. Just an idea.