06 Dead Starter, not the starter

[BDRider]

If it's confusing, it's a Big Dog!
Looked thru all the post for last couple hours. Here's what I've got.
One month old HD battery holding at 12.45V. All of the function work as they should prior to hitting the start switch. Green flashing, yellow steady on EHC. Hit the start switch, the red ign light ncomes on on the EHC, The compression releases click, no start.
Wire at the solenoid has no power. Let it sit for 2 min, 2hrs or 2 days, hit the start button and it fires right up. It may start 2 or 10 times, but then it wont start again for either minuets, hours or days.
Took off the gas tank, checked every wire end and every connection. Cleaned and or greased. Same on EHC. Same problem. maybe it'll start, maybe it won't.
Dealer said it was the VR, replaced it. Nope!
Any ideas or found issues?
Thanks guys!

 

[Analog]

If it's confusing, it's a Big Dog!
Looked thru all the post for last couple hours. Here's what I've got.
One month old HD battery holding at 12.45V. All of the function work as they should prior to hitting the start switch. Green flashing, yellow steady on EHC. Hit the start switch, the red ign light ncomes on on the EHC, The compression releases click, no start.
Wire at the solenoid has no power. Let it sit for 2 min, 2hrs or 2 days, hit the start button and it fires right up. It may start 2 or 10 times, but then it wont start again for either minuets, hours or days.
Took off the gas tank, checked every wire end and every connection. Cleaned and or greased. Same on EHC. Same problem. maybe it'll start, maybe it won't.
Dealer said it was the VR, replaced it. Nope!
Any ideas or found issues?
Thanks guys!

Terry, the wire at the solenoid that you are checking for voltage, is it the green wire? With the volt meter, did you pull the wire off and accually insert meter prob into spade terminal, hit the start button and check for voltage, having a good ground? The reason I ask, my starter went on the fritz and I was checking for voltage at the green wire just by probing at the starter. Had no voltage and though it my have been something from the EHC. To double check myself I pulled the wire off and probed in the spade terminal and had voltage when hitting the start button. The problem was I wasn't making terminal contact while wire was on the starter.

Have you noticed any oil dripping from the bottom of the starter? Oil can ruin a starter! I think that is what took mine out, its going back for a rebuild, will know soon.

When I was in contact with Accumax on my starter they told me they had one come back that water had gotten into the motor brushes resulting in damage. Has your bike seen exsesive water?

Just a few notes!

 

[BDRider]

No start

No water, but I'll double check for oil in the starter and voltage at the wire. Thanks

 

[Analog]

No water, but I'll double check for oil in the starter and voltage at the wire. Thanks

OK, let us know how you make out! I would clip your volt meter neg. right to the battery neg. so you have the best ground possible! This may be a little off, but make sure your meter is set to DC as well, this can easily be missed in a state of panic trying to find a problem! Been there and done that myself!!

:2thumbs:

 

[Little-Boo]

Could also be the circuit board on the hand controls. If you don't get power to the Green wire when you hit start you problem could be at the hand control circuit board. :2thumbs:

Carlos

 

[BDRider]

No power/solenoid

Green wire at solenoid has intermittent power. Sometimes it does, sometimes it doesn't. When it doesn't, the only thing that happens is the compression release activate, but no start.

 

[Analog]

Green wire at solenoid has intermittent power. Sometimes it does, sometimes it doesn't. When it doesn't, the only thing that happens is the compression release activate, but no start.

If you are getting intermittent voltage at the spade connector, (green wire), I would check the wire crimp at the connector make sure it’s not corroded or lose, if that is OK you will need check the connectors linking your EHC to the right hand controls and ignition switch. Make sure they are clean; no pins lose and connected properly. Do you have a service manual for your bike that you can access the wiring schematic for color code and proper connector’s to check?

When you were getting your intermittent voltage what was your procedure?

Example: Turn key on, hit the run button, and hit the start button.

Voltage -Yes or No?

If no did you turn off key and go through the start sequence again or did you just hit the start button again? Just trying to pin point the trouble, looking for possible consistent variable or other causes!

Any and all information on what exactly you did will help!

 

[BDRider]

06 BD

Turn on key, hit run switch, hit start switch. Testing wire before spade terminal. If it doesn't start there will be no power in the green wire while holding in the start switch. If it turns over, power is there.
Turn the key off and go thru it again, maybe it'll turn over maybe not. I have checked every wire and pin connector on the entire bike. Both handlebar switch controls, ECM connections.
Now this morning, it wouldn't turn over. Checked 20 times, no start. About 4:00, tried again and it now turns over. Checked it 13 times now. Still works.
Tomorrow it won't. It kept turning over, periodic tries, untill the batt was at 11.8 volts and it still tried to turn over then untill the lites flashed and the horn sounded. Did that several tries. I know that is low batt voltage.

 

[Analog]

Turn on key, hit run switch, hit start switch. Testing wire before spade terminal. If it doesn't start there will be no power in the green wire while holding in the start switch. If it turns over, power is there.
Turn the key off and go thru it again, maybe it'll turn over maybe not. I have checked every wire and pin connector on the entire bike. Both handlebar switch controls, ECM connections.
Now this morning, it wouldn't turn over. Checked 20 times, no start. About 4:00, tried again and it now turns over. Checked it 13 times now. Still works.
Tomorrow it won't. It kept turning over, periodic tries, untill the batt was at 11.8 volts and it still tried to turn over then untill the lites flashed and the horn sounded. Did that several tries. I know that is low batt voltage.

RDRider, Do you have a service manual for your bike? I was looking mine over last evening, 08 K-9, if you have continuity through the run button the problem is pointing toward the EHC. They recommend pulling the back bone harness, inserting the brake out box and checking proper numbered pins. I'm sure you don't have the break out box laying around but you should still be able to pull the harness and insert same hat pins in the head, clip on and check continuity that way, sorry I'm at work and do not remember the number pin for this check. If you what it I will post this evening, not sure if it’s the same for you model. You would have to do this when bike is on the blink, not starting. If no continuity, it may be your run - start PCB controls being intermittent. If there is continuity according to the service manual it’s pointing to you EHC. I checked out the trouble shooting section as well, according to the flow chart this is there procedure. I know this isn't much help in this situation, intermittent problems are very hard to pin point. If I think of anything else I will let you know. Maybe someone else here has an idea of where to go at this point. I'm scratching my head along with you!

 

[BDRider]

Thanks. It'll give some place else to look.

 

[Raywood]

Thanks. It'll give some place else to look.

There is a trouble shooting guide from BDM posted on here in the Tech section I think

 

[Analog]

Terry, Sorry I couldn't be of more help, here are the copies of information from my manual. Maybe this will help you!

 

[Analog]

More information:

 

[Analog]

Terry the pictures are a little hard to make out, save them to your desk top and you can zoom in when opened! Also the information is for a non EFI set up, if you have EFI let me know and I will scan those for you!