2004 Chopper Compression Release Click and nothing else!

[Trashman]

Been chasing a problem on my 04 chopper. Symptom: Turn key on, hit run button and then start button and all I get is a click. I put my fingers on starter solenoid cover and cannot feel solenoid when I get clicking sound. Placed fingers on front and rear compression releases and I can feel the compression release plungers when starter button is hit. Click is NOT coming from starter. Today, installed new HD battery and same thing. Voltage measurements: (Across battery post with tender plus connected) Key Off: 13.042 Vdc. Key On: 12.580 Vdc. Starter Button Engaged: 12.225 Vdc. Checked green solenoid wire, clean and tight. Removed solenoid cover last week, very minor pitting on all contacts. Cleaned, lubricated and reassembled. I also noticed that, at times, I may not get the red power LED on the EHC when I hit the run button. In the past, I have noticed that if the red power LED does not come on and stay on you can forget about the bike starting. I am in the process of searching resources on the site for troubleshooting this problem. Any direction in chasing this problem is appreciated.

 

[Trashman]

Measuring the Green solenoid wire: Key Off: 0.0Vdc, Key On: 0.0 Vdc, Key On & pressing the start switch: 12.4 Vdc...

 

[Trashman]

Still in need of help troubleshooting this problem. Many threads on the site lead to many differant directions. Please help!

 

[chacha]

Check lines to the Started - tight?

You say you can feel the CRs - are they dropping down when you hit start?

If you manually push the CRs in, does the bike start?

If the electrics are tight, the motor should at least turn over with the starter regardless of the positions of the CRs.

 

[Trashman]

Chaca, I can feel the CR's drop when I hit the start button. Bike will not start, starter does not engage, after pushing down of CR's. I just came back in from the garage after removing the solenoid cover. Can I manually push in on solenoid plunger a see if starter engages???

 

[BigDogBro1]

Sounds like the solenoid is not getting pulled in. Locked up solenoid or it went bad. Voltage at solenoid green wire looks ok.

You could remove the GREEN solenoid harness wire and try a jumper wire to the solenoid green wire connector direct from battery + side.

You should be able to push in on the solenoid but when you do the starter should spin up and crank the engine. If the solenoid is bound up it may not return back and stop cranking. Disconnect the battery first and push in the solenoid to see if it backs out ok, then connect back the battery and try again.


TRANS IN NEUTRAL.
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[Trashman]

BigDogBro1,

I did end up pulling the solenoid again, had done that a week earlier, cleaned and lubricated. When installing the solenoid plunger, I pushed it in to make contact and it DID make contact! I about crapped my pants when the solenoid latched in and the starter kept spinning. I popped the solenoid out with a screw driver to get it to disengage. All of this happened BEFORE your post so yea the battery was connected and a lesson was learned! Bottom line, it may have been the solenoid causing the problem. After I reassembled everything the solenoid, starter, EHC, etc seem to be working flawlessly. I once again have to rebuild my confidence level that the bike will start when I need it to. So far it has not left me standed although last week was close. Stopped for fuel and received the dreaded click, click! I kept trying and finally the starter spun and I headed for the house! Appreciate your help.

 

[Henderland1951]

Been chasing a problem on my 04 chopper. Symptom: Turn key on, hit run button and then start button and all I get is a click. I put my fingers on starter solenoid cover and cannot feel solenoid when I get clicking sound. Placed fingers on front and rear compression releases and I can feel the compression release plungers when starter button is hit. Click is NOT coming from starter. Today, installed new HD battery and same thing. Voltage measurements: (Across battery post with tender plus connected) Key Off: 13.042 Vdc. Key On: 12.580 Vdc. Starter Button Engaged: 12.225 Vdc. Checked green solenoid wire, clean and tight. Removed solenoid cover last week, very minor pitting on all contacts. Cleaned, lubricated and reassembled. I also noticed that, at times, I may not get the red power LED on the EHC when I hit the run button. In the past, I have noticed that if the red power LED does not come on and stay on you can forget about the bike starting. I am in the process of searching resources on the site for troubleshooting this problem. Any direction in chasing this problem is appreciated.

reply from Doug, Chesterland Ohio.
I’ve had this same problem for two years. Starting the bike was not reliable and was always afraid to go anywhere further away from local. Hit the start button and the starter would engage but not turn over the engine. Sometimes would have to hit the button 10-15 times to get it to start. My bike is a 2007 K9. I replaced the starter $300, and still would not Turn over the engine, took my battery in and the battery place tested it and said it was perfect. Checked all the wiring, replaced the ground from battery to starter. I’ve got years of troubleshooting engines and just could not figure it out. I made a starter button that wired directly from the battery to the solenoid. Still would not start. So here’s what the problem was. Two years ago I replaced the battery with a 20L gel battery, 310 amp battery seller said the gel was as good or better than my old dead original battery. Do not use a gel battery, the original battery was a glass mat 20 L, which is also 310 amps. So I said what the hell and spent another 150 bucks on a glass mat DEKA battery. I installed it and the bike started first hit of the handlebar button and has not failed me in the last month. It was that gel battery that caused the problem. Stay away from gel batteries. Two years of suffering because of the battery type.!

 

[Mickmorris]

reply from Doug, Chesterland Ohio.
I’ve had this same problem for two years. Starting the bike was not reliable and was always afraid to go anywhere further away from local. Hit the start button and the starter would engage but not turn over the engine. Sometimes would have to hit the button 10-15 times to get it to start. My bike is a 2007 K9. I replaced the starter $300, and still would not Turn over the engine, took my battery in and the battery place tested it and said it was perfect. Checked all the wiring, replaced the ground from battery to starter. I’ve got years of troubleshooting engines and just could not figure it out. I made a starter button that wired directly from the battery to the solenoid. Still would not start. So here’s what the problem was. Two years ago I replaced the battery with a 20L gel battery, 310 amp battery seller said the gel was as good or better than my old dead original battery. Do not use a gel battery, the original battery was a glass mat 20 L, which is also 310 amps. So I said what the hell and spent another 150 bucks on a glass mat DEKA battery. I installed it and the bike started first hit of the handlebar button and has not failed me in the last month. It was that gel battery that caused the problem. Stay away from gel batteries. Two years of suffering because of the battery type.!

Deka is the only way to go! Glad you got it sorted out!

 

[Jay Dawg]

I had the same thing happened on my 06 mastiff, I heard the clicking while hitting the start button, I also found that the compression releases was what was making the noise. I put the bike in gear and rocked back-and-forth, and then it worked normal. I have not had it happen since but like you I have no explanation as to why the starter does not engage but the compression releases are activated. Sorry I just saw this was 2010 post.