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1987 Evolution Starter

Discussion in 'Motorcycle Tech Talk' started by Paul C, Nov 7, 2011.

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  1. Paul C

    Paul C New Member

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    Here is a new one for me. The last two times I went to start my 1987 FLHTC the starter would not stop turning. I turned off the ignition and the engine stop switch but it would not stop. both times the solenoid or starter started smoking.

    I'm not sure how to test the switch unless you do it at the relay? Anyone else had this happen and was able to fix?
    Paul C, Nov 7, 2011
    #1
  3. Wideglide85

    Wideglide85 Active Member

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    Sounds like the starter relay is sticking. The contacts in there get burned and weld themselves together.
    Wideglide85, Nov 8, 2011
    #2
  4. hotroadking

    hotroadking Super Moderator Staff Member

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    once you let the smoke out they are shot.

    You'll need to rebuild the solenoid or replace the starter if it's shot.
    Custom Chrome has rebuild kits, most indys carry the kits call around
    and rebuild the starter.

    I would check with a meter the start button switch and wires to make
    sure they are all in good working order then install starter with
    new kit.
    hotroadking, Nov 8, 2011
    #3
  5. Tommyc

    Tommyc Active Member

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    Maybe the solenoid is sticking? Try jumping it with a screw driver. That by passes the relay. Is it does the same thing then it's prolly the solenoid.
    Tommyc, Nov 8, 2011
    #4
  6. Paul C

    Paul C New Member

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    Thanks Guys. Tommy C, I totally forgot about that trick from my childhood. It certainly worked on my old cars! Time to charge up the battery again and see...i'll report back later.
    Paul C, Nov 9, 2011
    #5
  7. Paul C

    Paul C New Member

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    Well a month has past and I bought a new battery and changed the solenoid but as I was torquing the cables onto the solenoid I cracked the cover. $85.00 down the drain. I was able to confirm that the starter is shot so I just received the newest solenoid and a new Hitachi starter. The only thing that seems unclear is whether the starter housing has to be removed or not....my manual makes it seem like I take the starter apart in order to remove it? Do I need to remove the primary?
    Paul C, Dec 9, 2011
    #6
  8. hotroadking

    hotroadking Super Moderator Staff Member

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    On big twins you have to drain primary and remove bolt from jackshaft to get starter out

    Two Allen's on starter side one bolt inner primary jack shaft

    Get a sm so you know tq values and pattern


    Sent from my iPhone using Tapatalk
    hotroadking, Dec 9, 2011
    #7
  9. Paul C

    Paul C New Member

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    Thanks hotroadking! I've got the SM but it's old and a little mysterious?? I guess it's time for a little more wrenching!
    Paul C, Dec 9, 2011
    #8
  10. hotroadking

    hotroadking Super Moderator Staff Member

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    that means the cover has to come off but not the the whole primary forgot to add that
    and there is a coupler between the starter jackshaft and the starter spline shaft and
    goes on a specific way, it also likes to fall off and land on the belt
    so be careful pulling the starter away so you don't loose it

    Not a hard job to do
    hotroadking, Dec 9, 2011
    #9
  11. Paul C

    Paul C New Member

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    This bike is driving me MAD! Since December I moved on to a few other projects and just came back to the bike with brand new starter motor, solenoid, starter relay, battery, battery and starter cables and the bike starts with the starter motor still engaged. I turn off the engine kill switch and the starter continues to turn the engine over until the battery dies.

    Any thoughts? It seems like the only thing I haven't done is replace the starter switch. I'm lost and annoyed, LOL!
    Paul C, Apr 27, 2012
    #10
  12. hotroadking

    hotroadking Super Moderator Staff Member

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    If the starter is running on the green wire to the starter is not dropping
    power, that is a switched wire,

    Pull it off the starter, put a multimeter on it and check for voltage with the
    key off, if it's present you may have a stuck starter relay in the closed (power on) position or a wire shorted sending power.

    If no power, then turn on dash ignition, do you have power, if yes, then the relay
    is getting a signal or, is stuck open, turn off power,

    Now remove relay but keep wires on it.
    put the meter on the relay where it gets power from the battery/fuse block
    is it hot?

    Check the switch other side from the hot, it should not be hot unless
    the start button is pressed, if it is hot, then the relay is probably shot,
    cheap and easy to replace, any auto parts store.

    Check the power in switched side of relay (power from start button)
    with dash on, if the button is not pressed and you have power coming from the start button on that wire, then the starter button may be bad.

    Electricity works in a circuit, follow the wires back to where things are good to find the bug.
    hotroadking, Apr 27, 2012
    #11
  13. Paul C

    Paul C New Member

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    This 1987 starter has only one cable running to it from the solenoid. The solenoid is a separate unit that has the positive cable from the battery connected along with 1 other wire on the long stud. On the middle stud it has another wire and on the lower stud is the cable to the separate starter.
    Paul C, Apr 28, 2012
    #12
  14. Tommyc

    Tommyc Active Member

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    Correct. The middle stud wire is from the relay. When the relay is energized from the starter button is activates the solenoid which then fires the starter.
    Test the relay like HRK said to see if it's bad. Prolly is. Or just go buy another one and swap it out. They go bad often. :rant:
    Tommyc, Apr 30, 2012
    #13
  15. Paul C

    Paul C New Member

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    I guess it's time to buy an ohmmeter. Thanks guys, I'll test the relay first.
    Paul C, Apr 30, 2012
    #14
  16. Tommyc

    Tommyc Active Member

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    A new relay is a lot cheaper than an Ohmeter. Anyway all you need is a test light, not ohmeter.
    Tommyc, Apr 30, 2012
    #15
  17. hotroadking

    hotroadking Super Moderator Staff Member

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    hotroadking, Apr 30, 2012
    #16
  18. Tommyc

    Tommyc Active Member

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    I wouldn't reccomend Harbour Frieght Tools to my worst enemy.
    They're okay for you tho HRK, Heehee.
    Cheap garbage!!!!!!!! :puke:
    I looked on Ebae and found a Snap-on multi meter. Can't go wrong with snap-on.
    The harbour frieght stuff usually breaks the first time you use it, sometimes before you use it.
    Buy American tools people!! Not Chinese junk.
    Tommyc, Apr 30, 2012
    #17
  19. hotroadking

    hotroadking Super Moderator Staff Member

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    yolou clazzy
    I no workie for living, I jlus workiee on fun

    Halbooor Flaight trrools velly velly good...
    hotroadking, Apr 30, 2012
    #18
  20. Tommyc

    Tommyc Active Member

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    I had a chinese girlfriend once, after sex I was horny again an hour later. :roflmao:
    Tommyc, Apr 30, 2012
    #19
  21. hotroadking

    hotroadking Super Moderator Staff Member

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    [YOUTUBE]JEEWE7gcPw0[/YOUTUBE]
    hotroadking, Apr 30, 2012
    #20
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