I've been pulling my hair out on this one for awhile. I have been working on an '84 Dresser Starter. Replaced Starter, replaced relay, replaced solenoid, disassembled and inspected jack shaft and gears, replaces bendix (drive gear),, everything I could think of. When I went to start the bike the starter acted like it was dragging and then WELDED ITSELF IN THE ENGAGED POSITION! I was freakin' out trying to pull the seat and negative battery wire before the starter motor reached critical mass. Got everything turned off okay and went in and replaced starter solenoid - again. Starts okay now but I'm scared to give it back to the customer for fear that it will lock up on him and burn up his new starter motor. Anybody else ever seen this problem that might give me a few suggestions? BTW I'm new here but this looks like a great forum. Thanks, DUb

 

When you say 'welded' are you talking about the washer welding itself
to the two contacts inside the solenoid? That was a common problem
back then. I have an '84 and it happened to me several times. Once I was
at a demo ride event and it happened to one of the demo bikes too.
The cause was low battery voltage would cause the solenoid plunger
to move slower than normal and then arc inside the solenoid, welding the
washer to the two contacts, which kept the starter motor turning until
the battery ran down completely.
Fix was to use a different type of washer in the solenoid. I guess not a
zinc washer or something. And to keep the battery charged. Personally,
I never had this problem after I switched to an Accel solenoid.

On the other hand, maybe you are talking about a totally different issue here.

 

I would say with about 98% that you have a bad ign switch. This was a very common problem. You need to chek votlage in and then out, then from relay, to solenoid. Ihave seen that over and over again, in fact it I remember correctly there was either a recall or a tsb on that, sorry been too long ago. Switch is pricey over 100 dollars so check it out first.

 

Yes, solenoid welding is the problem. Since the original post I went ahead and replaced the solenoid, again, with a brand new Accel - starts okay but still acts like it's dragging. I'll check voltage at the ignition switch and seewhat I get.

 

Sorry for the late post,if you have any more trouble,post it and we will go thru your system with some voltagedrop tests and cover the switch,relay and solenoid cicuits and figure it out.As long as you have a meter were good to go,Bob

 

My 85 FLT had the same problem. Turned out to be a small relay in the starter circuit. Went to the dealer bought the relay, plugged it in, no more problem.

 

Dub--I'm in your area (Horse Creek, Grand Lake.) Recently saw one of your ads locally and have been meaning to call to find your location. Please view my recent post re:: hard starter. No replies yet, still blowing my mind as to nature of trouble.

Lakebum, Grand Lake, OK.