Differences

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--- techtalk:evo:engctl02 [2018/05/21 09:35]
ixl2relax [Starter & Solenoid Function]
+++ techtalk:evo:engctl02 [2024/01/03 05:31] (current)
hippysmack
@@ Line 3: / Line 3: @@
 ====== STARTER & SOLENOID ASSEMBLY ======
+\\
 ===== Starter & Solenoid Function =====
-The starter system consists of the following components: Starter Switch, Starter Relay, Starter Solenoid & Starter Motor, the last two being combined into a unit. The starter power rating is 1.2kW. ((2010 & 2015 HD Police models brochure))
+The starter system consists of the following components: Starter Switch, Starter Relay, Starter Solenoid & Starter Motor, the last two being combined into a unit. The starter power rating is 1.2kW.((2010 & 2015 HD Police models brochure)) These starters are made by Nippon Denso.
 The Starter Switch is activated from the right handlebar switch housing. It is fed power when the Run/Stop switch is in the RUN position. When pressed, the Starter Switch (button) supplies power to the Starter Relay, which is located near the fuses. When activated, the Starter Relay will supply, thru it's controlled contacts, power to the Starter Solenoid. Starter Relays are subject to corrosion and oxidation. Since they are relatively inexpensive, the Starter Relay should be replaced every 5-years or sooner if there is any question of its operational functionality.
@@ Line 17: / Line 19: @@
 The high-amperage contacts will activate the starter motor. Typical starter current draw will range from 160 to 200 amps. If starter current draw exceeds 250 amps, the problem may be in the starter or starter drive. Remove starter for further tests.
-Off Bike - Free Spinning Starter Motor ((http://xlforum.net/forums/showthread.php?t=182342 Post 166 & 173))\\
+Off Bike - Free Spinning Starter Motor ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/47652-81-project-xlh1000?t=182342 Post 166 & 173))\\
   * Starting = 92amps
   * Running == 60amps
@@ Line 23: / Line 25: @@
   * Starting = 160-200amps
   * Running == 145-215amps (Inverse of Voltage Level)
-Technical Note - The pull-in windings are needed to initially move the plunger. Both the pull-in and hold-in windings are activated when the starter relay activates the solenoid. The power to the pull-in windings completes its path to ground thru the motor windings, while the hold-in windings have their own permanent ground path. Once the plunger moves forward into position, and the high-amperage contacts are closed, the pull-in windings are essentially disabled because the power on the output contact **(B)** makes both sides of the pull-in winding equal to 12v. This leaves only the magnetic field of the hold-in windings to keep the plunger in place.
 There are three external cable connections at the Starter Solenoid (see the diagram below):\\
-**(A)** Cable From the Battery Positive Terminal - This direct cable supplys high current for the internal solenoid contacts.\\
+**(A)** Cable From the Battery Positive Terminal - This direct cable supplys high current for the internal solenoid contacts **(B)**.\\
-**(C)** Cable to the Starter Motor - This is a short, high-amperage cable connecting the internal solenoid contact **(B)** to the starter motor (the cable is part of the starter/solenoid assembly).\\
+**(C)** Cable to the Starter Motor - Short, high-amperage cable as part of the starter/solenoid assembly.\\
 **(E)** Cable From the Starter Relay - A 12v positive signal.\\
-The internal contacts **(B)**, **(D)** & **(B)** create a high-current switch, which is operated by the plunger as it moves the pinion gear forward. When the plunger moves sufficiently forward, the plunger contact plate **(D)** is brought into contact with both **(B)** contacts, thus acting as a switch to provide direct battery power from contact **(A)**, thru contacts **(B)**, and out contact **(C)** to the starter motor.
+The internal contacts **(B)**, **(D)** & **(B)** create a high-current switch, which is operated by the plunger as it moves the pinion gear forward. When the plunger moves sufficiently forward, the plunger contact plate **(D)** is brought into contact with both **(B)** contacts, thus acting as a switch. This provides direct battery power from contact **(A)**, thru contacts **(B)(D)(B)**, and out contact **(C)** to the starter motor.
 Here's a diagram of the Starter/Solenoid Assembly:
 {{techtalk:evo:elec:starter-solenoid-81up.jpg}}
-The high-amperage internal solenoid contacts are shown in that diagram at the connection labeled '8'. The solenoid activation circuit (which includes the Starter Switch and the Starter Relay) is identified simply with the dotted line near '10'.
+Technical Note - The pull-in windings are needed to initially move the plunger. Both the pull-in and hold-in windings are activated when the starter relay activates the solenoid. The power to the pull-in windings completes its path to ground thru the motor windings, while the hold-in windings have their own permanent ground path. Once the plunger moves forward into position, and the high-amperage contacts are closed, the pull-in windings are essentially disabled because the power on the output contact **(B)** makes both sides of the pull-in winding equal to 12v. This leaves only the magnetic field of the hold-in windings to keep the plunger in place.
+In the left diagram above, the high-amperage internal solenoid contacts **(B)(D)(B)** are labeled '8'. The solenoid activation circuit (which includes the Starter Switch and the Starter Relay) is only identified with the dotted line from the battery to the windings at '10' & '11'.
 When the solenoid plunger moves the pinion gear ('1') into mesh with the ring gear('13'), the starter motor is already starting to turn and helps the gears to mesh laterally. Once engaged, the starter motor will continue to rotate the ring gear (as long as the starter button is pressed) until the engine fires. At that point, the overrun clutch ('12') in the solenoid gear assembly allows the ring gear to run faster than the pinion gear shaft without harming the starter unit. When you release the starter button, the solenoid will retract the pinion gear from engagement with the ring gear and the starter unit will return to a resting state.
+<font 20px/Arial, , ;;#ff0000;;>WARNING! DANGER! When Replacing Battery Cable On The Solenoid</font>
+It is critical (repeat: CRITICAL) to be sure the alignment of the internal high current contact is not disturbed when mounting the Positive Battery Cable to the solenoid. As the picture shows, the stud on which the battery cable is mounted goes inside the solenoid housing and is actually part of the contact. If that stud rotates when you tighten the nut for mounting the battery cable, the internal contact will rotate also, placing it in the improper alignment to the contact ring (D) on the solenoid plunger.
+**THIS IS LIKELY TO CAUSE A DANGEROUS ISSUE WHEN TRYING TO START THE ENGINE.** It is likely to contact at one small point, rather than over the whole contact surface, and weld itself to the contact ring (D). This in turn will cause the starter to run continuously because there are no switches or fuses that can stop the current flow if the solenoid contacts (which IS the high current switch) are welded together.
+**THIS IS VERY DANGEROUS!** The battery will produce maximum current flow in the hundreds of amps. It may explode or puff up inside the cover as it self-destructs from the overload condition. ([[http://xlforum.net/forums/showthread.php?t=2077912|CLICK HERE to see a thread at the XLForum about this problem]])((Thanks to CCC for posting what happened.))
 \\
@@ Line 45: / Line 56: @@
   * 20amps pulled thru the Starter Relay (to the Starter Solenoid Coil)
   * 200amps pulled thru the Starter Solenoid Hi-Current Contacts\\ (to the Starter Motor when engaged with the Ring Gear)
+  * Also review this Sportsterpedia section: [[techtalk:evo:elec02#relays]]
+{{:techtalk:evo:engctl:startercurrentdraw.jpg?450|}}
 \\
@@ Line 129: / Line 142: @@
 Use another jumper wire from the NEGATIVE battery terminal to the case of the solenoid body and secure it well.
-**Double Check for Safety** - At this point, you should have no connection at the Battery Positive Post and no connection at Solenoid Connection 'A' - The jumper wires are connected to Solenoid connections 'C' and 'E' with a ground wire from the solenoid body connected to the NEGATIVE battery post.
+**Double Check for Safety** - At this point, you should have no connection at the Battery Positive Post and no connection at Solenoid Connection 'A' - The jumper wires are connected to Solenoid connections 'C' and 'E' plus a ground wire from the solenoid body connected to the NEGATIVE battery post.
 \\
@@ Line 181: / Line 194: @@
 Naturally, aftermarket kits are available - check those for compatibility.
-**Caution**\\
+\\
-through 1990 Big Twin ..... use Kit 31608-90\\
-and later Big Twin ........ use Kit 31604-91\\
--06A (Black), 31621-06A (Chrome) 1.4KW Starter((See HD Instructions -J04280 2009-06-04))
+**Caution Related to BT Starter Versions**\\
+-06A (Black), 31621-06A (Chrome) 1.4KW Starter ((See HD Instructions -J04280 2009-06-04))
 This starter is defined to fit 2006 and later Dyna, and 2007 and later Softail and Touring model motorcycles.
 From examining the solenoid rebuild kit (31604-06) for this model, it appears the solenoid plunger rod is longer than that used with the Sportster 1.2KW stock model starter. So this kit may not work with the XL models.
+Rebuild Kits:\\
+through 1990 Big Twin ..... use Kit 31608-90\\
+and later Big Twin ........ use Kit 31604-91\\

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