harley davidson starter motor problems

harley davidson starter motor problems

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Harley Davidson Starter Motor Problems: Encyclopedia-Style Overview

Common Starter Motor Problems in Harley Davidson Models

1. Starter Doesn’t Engage (No Electrical Response)

• Symptoms: Turning the key produces no sound from the starter; dashboard lights may dim or stay off.


• Primary Causes:
  
  
  
  • Dead Battery or Loose Cables: Corroded terminals, loose connections, or a discharged battery (common in older models left unused).
  
  
  • Faulty Starter Relay: The relay (often located near the battery or under the seat) may fail due to electrical surges or age.
  
  
  • Ignition Switch Failure: Internal contacts wear out, preventing power from reaching the starter.
  
  
  
  


• Harley-Specific Note: Models like the Softail or Touring series may have hidden relay locations, requiring removal of body panels for access.

2. Starter Spins but Doesn’t Crank the Engine (Solenoid Engagement Issue)

• Symptoms: A clicking noise or whirring sound is heard, but the engine does not turn over.


• Primary Causes:
  
  
  
  • Starter Clutch Failure: The overrunning clutch (which transfers starter torque to the engine) wears out, slipping during engagement.
  
  
  • Broken Pinion Gear: The small gear on the starter shaft may strip or crack, failing to mesh with the engine’s flywheel gear.
  
  
  • Solenoid Malfunction: The solenoid plunger sticks, preventing full extension of the pinion gear.
  
  
  
  


• Model-Specific Example: Harley Davidson Evolution (1984–2001) engines often experience starter clutch wear due to heavy torque loads.

3. Grinding or Whining Noises During Start-Up

• Symptoms: A harsh grinding sound when the starter engages, often indicating gear misalignment or wear.


• Primary Causes:
  
  
  
  • Misaligned Starter Mount: Vibrations can loosen the starter bolts, causing the pinion gear to miss the flywheel.
  
  
  • Worn Flywheel Ring Gear: The large gear on the engine’s flywheel may develop chips or flat spots, conflicting with the pinion.
  
  
  • Lack of Lubrication: Dry bearings in the starter motor cause excessive friction and noise.
  
  
  
  


• Note: Twin Cam models (1999–2017) may require shimming the starter to adjust gear alignment during replacement.

4. Starter Overheats or Draws Excessive Amperage

• Symptoms: Starter feels hot to the touch, or the battery drains quickly after multiple attempts.


• Primary Causes:
  
  
  
  • Worn Brushes or Commutator: Electrical arcing inside the starter motor reduces efficiency and generates heat.
  
  
  • Seized Armature or Bearings: Mechanical resistance forces the starter to work harder, increasing amperage draw.
  
  
  • Electrical Short: A damaged wire or solenoid coil causes a short circuit, overloading the system.
  
  
  
  

Diagnostic Steps for Harley Starter Issues

1. 
   
   Electrical System Check
   
   
   
   
   • Test battery voltage (should read 12.4–12.6V at rest; 9.5V+ during cranking).
   
   
   • Inspect cables for corrosion, tightness, and continuity (use a multimeter to check for voltage drop at terminals).
   
   
   
   


2. 
   
   Relay and Switch Testing
   
   
   
   
   • Bypass the starter relay by jumping its terminals with a screwdriver (ensure the bike is in neutral and safety precautions are taken). If the starter engages, the relay is faulty.
   
   
   • Test the ignition switch with a multimeter to confirm power flow when turned to “Start.”
   
   
   
   


3. 
   
   Starter Motor Bench Test
   
   
   
   
   • Remove the starter and connect it directly to a fully charged battery (positive to solenoid terminal, negative to motor housing). If it spins smoothly without noise, the issue may be elsewhere (e.g., clutch or flywheel).
   
   
   
   


4. 
   
   Mechanical Inspection
   
   
   
   
   • Remove the starter and check the pinion gear for wear. On models with an external starter clutch (e.g., Sportster), inspect the clutch rollers and springs for damage.
   
   
   • Visually inspect the flywheel ring gear through the starter opening (use a mirror or borescope for hard-to-reach areas).
   
   
   
   

Repair and Replacement Costs

• Starter Motor Replacement:
  
  
  
  • Aftermarket/remanufactured starters for Harley Davidson: $100–$300 (e.g., for Sportster or Dyna models).
  
  
  • OEM Harley-Davidson starters: $200–$500 (higher for Touring or CVO models with premium components).
  
  
  
  


• Clutch and Gear Repairs:
  
  
  
  • Starter clutch kits: $50–$150 (DIY installation requires basic tools; labor adds $50–$100).
  
  
  • Flywheel ring gear replacement: $200–$400 (involves engine disassembly, costly for professional service).
  
  
  
  


• Labor Considerations:
  
  
  
  • Independent motorcycle shops: $75–$125/hour (1–2 hours for starter replacement).
  
  
  • Harley-Davidson dealerships: $100–$150/hour, plus higher OEM part costs.
  
  
  
  

Preventive Maintenance Tips

1. 
   
   Battery Care:
   
   
   
   
   • Use a trickle charger for long-term storage to avoid deep discharges, which strain the starter.
   
   
   • Clean and tighten battery terminals annually to prevent corrosion.
   
   
   
   


2. 
   
   Starter System Checks:
   
   
   
   
   • Lubricate the starter mounting bolts and electrical connections with dielectric grease to reduce corrosion.
   
   
   • For older models (pre-2000), inspect the starter clutch every 10,000–15,000 miles for wear.
   
   
   
   


3. 
   
   Starting Practices:
   
   
   
   
   • Avoid excessive cranking (limit to 10-second intervals) to prevent overheating the starter.
   
   
   • In cold weather, use a battery tender or let the bike warm up slightly before starting to reduce load on the starter.
   
   
   
   

Where to Source Parts and Expert Advice

• Specialized Retailers:
  
  
  
  • https://www.starterstock.com/: Offers remanufactured and OEM starter motors for Harley Davidson models, with detailed compatibility guides for Sportster, Touring, Dyna, and Softail series.
  
  
  
  


• Harley-Davidson Dealerships: For OEM parts and warranty-backed repairs, though at higher costs.


• Online Forums and Communities:
  
  
  
  • Harley Davidson Forums (e.g., HarleyDavidsonForum.com) provide DIY repair guides and user experiences with starter issues.