Bike in question '96 FLSTF

OK here is the full story. Many months ago went to start my bike, nothing, just the dreaded click. Ignition relay working etc, figured it was the solonoid....

Fast forward to this week and finally budget and time issues align (last year was a rough year) and I get a push button solonoid cover as an alternative to starting it. Oh and since doing that now it starts. I also got a solonoid rebuild kit, figured I might as well, but have not rebuilt it. I literally put the push button cover on without pulling any thing from the bike, well other than the battery, just to be safe.

SO I goto start it. Granted it has been sitting for a couple months, no oil leaks in its location in the garage. Starts but one under engine ignition (in nuetral) there is a horrible noise coming from the front left side. It seems to be at the engine end of the primary. The noise is not there when the starter is cranking, only once the engine gets under way. Haven't tried pulling in the clutch or anything yet to see if that changes the dynamic of, frankly wasn't sure that would since it was the front of the cover.

To describe the noise, well it is like a grinding but also like a clicking. Heck it almost sounds like a weird electrical arcing but it is definitely mechanical, at least to my ears.

My best guess is the compensator nut came loose. However to mention although it has been sitting when parked after the last ride there were no issues whatsoever on that ride. Any guesses or clues would be great.

Yes I have the service manual, and a lift, and I am not afraid to get dirty. Was planning to pull the primary cover saturday to figure out what the hell is up with it. Since I gotta pull that off now I figure I might as well do the full solonoid rebuild as well as there are numerous electrical things I would like to address that I feel were poorly done, binding wires and bad connections (well bad in my book, I take pride in my electrical work). Anyway I might even tear it down more and paint it like I have been thinking.

Ok rambling sorry, thanks for any help in advance.

Ken

 

Update: a couple things I just tried and noticed and a new theory.

1. The sound exists whether the clutch is pulled in or not.

2. it is coming from the primary over all and actually might be louder from there rear.

3. I think the culprit is the starter, as in when I installed that push button in it is holding the jack shaft in too far and that is the problem, the pinion is staying engaged or partly engaged in the motor and not coming back out as far as it needs to after starting.

So in theory if I slack that then I should be good to go, without even opening the primary case. Any other theories, I will probably put mine to the test tomorrow night. Mine is based on the fact that the sound is not present when starting but once the bike actually kicks over under its own ignition.

Ken

 

In my experiance when something goes wrong right after a repair it usually has something to do with the repair. I agree that the first thing you should check out is the starter. I also think you should pull the outer primary to check the starter jackshaft gear and the ring gear on the clutch hub just to be safe.

 

A push button install will not have a thing to do with the jack shaft. But sitting could make things not work properly. Need to do an exploratory and find out whats going on.

 

What you mean? I mean really I have never done that job before ever, I am not a certified mechanic but I got the service manual and the internet and I can do anything.

hehehehehe

Exactly, that was the part that bothered me about the first guess diagnosis, it lacked causality, and I consider "because I touched it" to be a perfectly reasonable causality. I learned a long time ago that a good rule of life is to second guess your own work before you second guess the work of others.

Ken

 

It is all in the same line/shaft though, isn't it. If the push button is not allowing the spring to release back all the way to the second spring tension then wouldn't that leave the pinion in the path of the ring gear?

Ken

 

I would pull the push button off and take a look inside the solenoid and in edge of plunger for " burn" marks. Sometimes with worn out contacts or the plunger the will temporary tack weld them selves and create a sticking problem wich could result in your noise

 

Will do, to be safe I am pulling the primary cover off to inspect and since that is coming off I am going to go ahead and rebuild the solenoid anyway since I already have the kit to do so on hand.

I consider that possibility unlikely for three reasons. When putting the cover on the plates looked pretty good. The noise in question does not sound like the starter is running while the engine is firing under it's own power. Lastly the newly installed push button is returning to full out position when finished so at minimum the solenoid is releasing contact to the plates for that to happen.

However I will check anyway.

Thank you.

Ken

 

Might be a magnet coming loose or disintegrating in the rotor/stator area. Check the voltage coming out the stator. (app. 20v a/c per 1000rpm)

 

Sounds like the compensator Sprocket to me....