Charging system testing- weak starter? just clicking? Is it the battery?

[Thumper]

Originally Posted by Do©Hawk

I pulled the body panels, seat, tank and headlight so I could scour over the wiring harness and connections. All seems well.

I pulled the starter. The spline end does not appear damaged. When I run jumper cables from the battery to the starter directly, I only get sparks at the post on the starter. No motion from the starter at all. Still measuring 13v from the battery.

Ooo. Sounds like a bad starter(grounding out somehow, or worn out brushes). Starters can be refreshed, but simplest thing is to replace it.

[Do©Hawk]

New one ordered.

[J4Fun]

If memory serves me correct dirtbkr188 brought up starter problems because of windings awhile back? Glad you posted your findings, we all get to learn! Just thinking out loud here and great thread for learning!

[Do©Hawk]

As embarrassing as it may be, I think I just had a loose cable.

Lesson learned (though I'm sure I'll need a refresher at some point)
Don't overlook the simple stuff creating a problem you don't have.

[Thumper]

Originally Posted by Do©Hawk

I pulled the body panels, seat, tank and headlight so I could scour over the wiring harness and connections. All seems well.

I pulled the starter. The spline end does not appear damaged. When I run jumper cables from the battery to the starter directly, I only get sparks at the post on the starter. No motion from the starter at all. Still measuring 13v from the battery.

Not sure how this (jumpers to starter) did not activate the starter if it was just a loose wire ?

Positive battery post to thick wire terminal and ground the body of the starter to the negative post, and the starter should run, with high torque! You do have to clamp it on there and if you don't, there will be sparks (high amperage device).

[Do©Hawk]

Maybe I never got the positive clamped onto the starter when I tested it directly to the battery?

[Do©Hawk]

Originally Posted by Do©Hawk

........Little bit of corrosion at the positive terminal.

I believe my problems started here, but the 1st symptom was the starter not engaging, but there were also some electrical issues that made me think wiring.

When I bridged the prongs on the starter solenoid with a screwdriver, I got sparks and smoke from the positive battery terminal and the terminal screw welded itself to the nut. After getting the screw and nut apart, I had a hard time getting that screw tight-tight, but I thought it was tight enough. I was wrong.

Fast forward to yesterday. Solenoid and relays received, still waiting for starter, but I cant leave well enough alone. Put in a relay, no change, not part of the problem. Disconnect the battery again, change solenoid, reconnected the battery and discover that the one nut and screw were wonky. I fuss with it for a bit and get it on and tight. Hit the starter button and it fires right up. OKayeee. Now I'm curious. Pull the new solenoid and put the old back on and it starts right up. No new parts necessary.

I think this was a perfect storm of lack of experience, pessimism, and some of my own Idiocracy. Parts purchased weren't much over $40, so I intend to keep them. Mistakes were made on my part, but lessons were learned. I'm just glad to have it running right again.

[Thumper]

It is surprising how often disconnecting each connection, wire brush, clean, reconnect throughout fixes things on an old bike!

[bigdano711]

I still have this waterproof electrical wiring connector kit in my save for later stuff on Amazon, but the wiring has been good so far. It happens to the best of us. Shake it off and RIDE!!


A little tip to help keep corrosion at bay: squirt a little WD40 on a rag and put a light coat over your battery terminals and connectors. Works pretty good.



https://www.amazon.com/gp/product/B0...DOR4AD1H&psc=1