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techtalk:evo:engctl02 [2019/04/19 20:28] ixl2relax |
techtalk:evo:engctl02 [2024/01/03 05:31] (current) hippysmack |
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| 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. | 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 | * Starting = 92amps | ||
| * Running == 60amps | * Running == 60amps | ||
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| 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. | 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. | ||
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| + | <font 20px/Arial, , ;;#ff0000;;>WARNING! DANGER! When Replacing Battery Cable On The Solenoid</font> | ||
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| + | 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. | ||
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| + | **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. | ||
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| + | **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.)) | ||
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| * 20amps pulled thru the Starter Relay (to the Starter Solenoid Coil) | * 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) | * 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|}} | ||
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| Use another jumper wire from the NEGATIVE battery terminal to the case of the solenoid body and secure it well. | 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. |
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| Naturally, aftermarket kits are available - check those for compatibility. | Naturally, aftermarket kits are available - check those for compatibility. | ||
| - | **Caution**\\ | + | \\ |
| - | 1989 through 1990 Big Twin ..... use Kit 31608-90\\ | + | |
| - | 1991 and later Big Twin ........ use Kit 31604-91\\ | + | |
| + | **Caution Related to BT Starter Versions**\\ | ||
| 31619-06A (Black), 31621-06A (Chrome) 1.4KW Starter ((See HD Instructions -J04280 2009-06-04)) | 31619-06A (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. | 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. | 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. | ||
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| + | Rebuild Kits:\\ | ||
| + | 1989 through 1990 Big Twin ..... use Kit 31608-90\\ | ||
| + | 1991 and later Big Twin ........ use Kit 31604-91\\ | ||
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