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techtalk:ih:engctl02 [2020/03/09 08:56] – [Solenoid] ixl2relaxtechtalk:ih:engctl02 [2023/12/31 18:18] (current) – hippysmack
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 Reference these threads:\\ Reference these threads:\\
-http://xlforum.net/forums/showthread.php?t=1521782 - Dr. Dick Post#4 quoted above\\ +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/140324-prestolite-hitachi-help?t=1521782 - Dr. Dick Post#4 quoted above\\ 
-http://xlforum.net/forums/showthread.php?t=1715008\\ +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/159854-starter-motors?t=1715008\\ 
-http://xlforum.net/forums/showthread.php?t=1752598\\+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/163098-starter-pipe-clearance?t=1752598\\
  
  
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 For additonal information, see the [[techtalk:evo:engctl02|Evo Section - Starter/Solenoid]] For additonal information, see the [[techtalk:evo:engctl02|Evo Section - Starter/Solenoid]]
  
-|  Prestolite Starter. ((photos by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27))  ||+|  Prestolite Starter. ((photos by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27))  ||
 |{{:techtalk:ih:engctl:prestolite_starter_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:prestolite_starter_11_by_sifty.jpg?direct&300|}}| |{{:techtalk:ih:engctl:prestolite_starter_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:prestolite_starter_11_by_sifty.jpg?direct&300|}}|
  
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 ====== Solenoid ====== ====== Solenoid ======
  
-A typical well-made solenoid as two windings connected to the small terminal. ((Oldwrench of the XLFORUM http://xlforum.net/forums/showthread.php?t=522413&page=2)) \\ +{{ :techtalk:ih:engctl:72-xlh-startersolenoid-operation.jpg?320|}} 
-One coil (HOLD-IN) goes to solenoid case ground and the other (PULL-IN) goes to the big terminal for the starter lead.\\ +A typical well-made solenoid as two windings connected to the small terminal. ((Oldwrench of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/74579-what-would-cause-the-solenoid-to-be-very-very-hot/page2?t=522413&page=2)) \\ 
-When you hit the starter button, battery voltage goes thru the starter relay into the solenoid small terminal, then goes\\ +One coil (HOLD-IN) goes to solenoid case ground and the other (PULL-IN) goes to a big terminal (starter lead).\\ 
-·· thru the 'PULL-IN' windings (which are grounded thru the starter motor) and thru the 'HOLD-IN' windings (to case ground).\\+When you hit the starter button, battery voltage goes thru the starter relay into the solenoid small terminal,\\ 
 +·· then goes thru the 'PULL-IN' windings (which are grounded thru the starter motor) and thru\\ 
 +·· the 'HOLD-IN' windings (to the case ground).\\
 **When these coils are activated together, they pull the plunger in.** **When these coils are activated together, they pull the plunger in.**
  
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 **Make sure that your connections are to the proper large terminals!** **Make sure that your connections are to the proper large terminals!**
  
-IT IS IMPORTANT that you use the __**Large Short** Terminal to connect to the Starter Motor__ and the __**Large Long** Terminal to connect to the Battery__. If the Large Terminals of your solenoid are not one Long & one Short, use a multimeter or test light to bench test which Large Terminal has some continuity to the Small Terminal. Whichever Large Terminal has some continuity to the Small Terminal is the one that is connected to the Internal PULL-IN Coil and is the one to be connected to the Starter Motor.+**IT IS IMPORTANT** that you use the __**Large Long** Terminal to connect to the Battery__ and the __**Large Short** Terminal to connect to the Starter Motor__. If the Large Terminals of your solenoid are not one Long & one Short, use a multimeter or test light to bench test which Large Terminal has some continuity to the Small Terminal. Whichever Large Terminal has some continuity to the Small Terminal is the one that is connected to the Internal PULL-IN Coil and is the one to be connected to the Starter Motor.
  
-If the large terminal connections are swapped, with the battery cable is connected to the output starter terminal of the solenoid,\\ +If the large terminal connections are swapped, with the battery cable connected to the output starter terminal of the solenoid, then the internal windings will be constantly conducting current. \\
-·· then the internal windings will be constantly conducting current. \\+
 That current isn't strong enough to actually pull in the plunger but the current flow is enough to make the solenoid get really hot. \\ That current isn't strong enough to actually pull in the plunger but the current flow is enough to make the solenoid get really hot. \\
-If left this way, and not disconnected, it will eventually burn out either/both the PULL-IN windings and the HOLD-IN windings\\ +If left this way, and not disconnected, it will eventually burn out either/both the PULL-IN windings and the HOLD-IN windings because they are wound together inside the solenoid.\\
-·· because they are wound together inside the solenoid.\\+
 So you don't want to hook up the battery to the terminal used for the starter. \\ So you don't want to hook up the battery to the terminal used for the starter. \\
 The solenoid will still work at first, but left connected it will burn out either or both of the windings because the windings are constantly conducting. \\ The solenoid will still work at first, but left connected it will burn out either or both of the windings because the windings are constantly conducting. \\
-Using an ohm meter would give really confusing readings because you'd see continuity to both case ground and the starter terminal\\ +Using an ohm meter would give really confusing readings because you'd see continuity to both case ground and the starter terminal from the solenoid windings connection.
-·· from the solenoid windings connection.+
  
-67 and Up XLH Starter solenoid (71469-65) \\ +\\ 
-Below, the 1/4" solenoid mounting threads were stripped (nut on the top bolt) so they were tapped out for 8mm cap screws. ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27)) \\+ 
 +**67 and Up XLH Starter solenoid (71469-65)**\\ 
 +Below, the 1/4" solenoid mounting threads were stripped (nut on the top bolt) so they were tapped out for 8mm cap screws. ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27)) \\
 8mm x 1.25 threads have almost exactly the same thread pitch as the original 1/4" thread. \\ 8mm x 1.25 threads have almost exactly the same thread pitch as the original 1/4" thread. \\
-Then the mounting bracket and and spacer were drilled 8mm and the solenoid was installed using allen head cap screws and spring washers. \\+Then the mounting bracket and and spacer were drilled 8mm and the solenoid was installed using allen head cap screws and spring washers.
  
-|  Starter solenoid (71469-65) ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27))  |||+|  Starter solenoid (71469-65) ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27))  |||
 |{{:techtalk:ih:engctl:solenoid_switch_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_2_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_3_by_sifty.jpg?direct&300|}}| |{{:techtalk:ih:engctl:solenoid_switch_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_2_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_3_by_sifty.jpg?direct&300|}}|
  
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- 
  
 ===== Check Solenoid Cover for Conductivity ===== ===== Check Solenoid Cover for Conductivity =====

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