1992 Sportster Starting Problems (Electrical)

Hi

OK - I've spent the better part of a day looking for a dead short or
something that is causing my 'click - no start' condition (1 click at
the starter relay, then nothing)

I've just installed a brand new battery, and also brand new battery
cables, and also installed a new main 30Amp circuit breaker

I've unplugged all lights from the headlight wire harness (removing
light system as possible short)

I've just checked voltage readings:
1) Battery voltage while pressing start button - 12.10 volts (a bit
low, probably from me performing lots of electric tests the past day)
2) '50' terminal wire at solenoid (wire with slide clip) while
pressing start button - 11.80 volts
3) Solenoid Terminal (post where positive battery cable mounts) while
pressing start button - 11.84 volts
4) Start Terminal (top of solenoid, connects wire from solenoid to
starter) - wanders from 3.50 to 3.80 volts

Hmmmm.... dead or shorted solenoid?

I did remove starter and cleaned up brushes and stuff - also performed
all test for shorts and grounds - starter seems fine

I did remove endplate to solenoid, notice the half-moon contact plate
was quite a bit pitted - I removed plate and sanded smooth -
reinstalled

Any advice? Replace or rebuild solenoid, right?

Thanks

mcreda2000 <mcreda2000 DeleteThis @cs.com> wrote in message
news:dbd74c7f.0407050947.3e5b4426@posting.google.com...
 > Hi
 >
 > OK - I've spent the better part of a day looking for a dead short or
 > something that is causing my 'click - no start' condition (1 click at
 > the starter relay, then nothing)
 >
 > I've just installed a brand new battery, and also brand new battery
 > cables, and also installed a new main 30Amp circuit breaker
 >
 > I've unplugged all lights from the headlight wire harness (removing
 > light system as possible short)
 >
 > I've just checked voltage readings:
 > 1) Battery voltage while pressing start button - 12.10 volts (a bit
 > low, probably from me performing lots of electric tests the past day)
 > 2) '50' terminal wire at solenoid (wire with slide clip) while
 > pressing start button - 11.80 volts
 > 3) Solenoid Terminal (post where positive battery cable mounts) while
 > pressing start button - 11.84 volts
 > 4) Start Terminal (top of solenoid, connects wire from solenoid to
 > starter) - wanders from 3.50 to 3.80 volts
 >
 > Hmmmm.... dead or shorted solenoid?
 >
 > I did remove starter and cleaned up brushes and stuff - also performed
 > all test for shorts and grounds - starter seems fine
 >
 > I did remove endplate to solenoid, notice the half-moon contact plate
 > was quite a bit pitted - I removed plate and sanded smooth -
 > reinstalled
 >
 > Any advice? Replace or rebuild solenoid, right?
 >
 > Thanks

electrical problems can really suck. try tapping your starter with a small
hammer while pushing the starter button. You may have a starter problem.
good luck,
walt
'91 fxr<!-- ~MESSAGE_AFTER~ -->