Hello,
I'm in the process of performing a number of maintenance items on my 1993 Fatboy. One of the maintenance items I took care of this week was installing the HD starter solenoid rebuild kit (HD #31604-91A). I've installed this same solenoid rebuild kit on my 2011 Ultra last year without any issues.
Now, when I try to re-start the Fatboy. I hear what sounds like the solenoid engaging, but nothing else. The starter motor doesn't spin. Battery is good. I'm seeing about 11.5 volts when I push the starter button. Where do you suggest I start to diagnosis this issue?
I'm not looking forward to pulling everything apart again. To get the starter out, I had to:
1. Remove rear exhaust
2. Remove outer primary.
3. Remove jackshaft
4. Remove battery
5. Remove debris deflector
6. Remove fasteners from oil tank to give me enough room to pull out the starter

 

I'd have the battery load tested. 11.5 may not be enough to pull the solenoid in enough to complete the contact to spin the starter motor.

Paul

 

Unless that's exactly what it was doing before, I'd start at where with the last thing you did - the solenoid.

And a low or weak battery is always suspect, though 11.5 on the factory gauge sounds about right when pulling the solenoid only.

 

I don't think it's the battery. The battery would start the bike before I began this work. I also just attached my Noco GB40 to the battery and tried to start the bike. No joy.

I think my issue has something to do with the jackshaft. Maybe I installed something incorrectly.
If I remove the outer primary, is it OK for me to try and start the bike and see if the jackshaft extends to the ring gear?

 

Remove the end cap from the solenoid housing and check to see if the stationary contacts have been installed level and the round copper contact on the solenoid plunger is engaging both of them and making a solid connection. You won't need to remove the starter to do this, but be sure to disconnect the negative battery terminal first.

 

Great idea! I removed the end cap. It does look like the contacts were installed level. I do recall and following the rebuild kit instructions which say:
While holding pressure on the plunger, tighten the nuts on the terminals. This will ensure alignment of the contact plates.

When I push in the plunger, it requires a considerable amount of force via my fingers. Is that normal?
I even installed the old plunger (with the spring), and it also requires a considerable amount of force to push in.

 

That was measured via my DVOM on the battery. This motorcycle doesn't have a volt gauge.

 

It takes a bit of force to push the plunger in. Are you getting adequate voltage to the "S" terminal (the green wire) on the starter when you push the starter button? Are both battery connections and all of the ground connections good?

 

I did hear what sounded like the solenoid moving when I hit the starter.
I'll follow your suggestions tomorrow. Thank you!
It's just very frustrating since as I mentioned I've rebuilt the solenoid on one of these HD starters before, and I had the bike completely back together and was hoping to go for a ride.

 

One last question for this evening. Is it ok/safe for me to install the plunger (and return spring) back into the solenoid, re-attach my battery ground cable, turn on the ignition and push the plunger with a wooden dowel to see if the bike starts?