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Bad Regulator/Bike Won't Start

Yes, I replaced the relay not the solenoid, I will try this on Saturday when I have time.

Does this mean that the solenoid is bad if the engine does not crank?

Thanks for the input!

If you jump across the solenoid and the bike does not crank you have a problem in the starter and or the solenoid, putting direct power cross the solenoid should turn it over
 
Does this mean that the solenoid is bad if the engine does not crank?

Don't jump to a conclusion. It all depends on what the meter reads when it happens.

That is why I wrote:
Watch the meter when you make contact with the jumper. Does the engine crank? If so what does meter read while cranking. If it does not crank, what does the meter read in volts while the jumper is in place.

Don't forget to have the bike in neutral.
 
Being a 1990 bike, the contacts in the solenoid could be causing the problem. There's quite a load that goes through them each time they ar energized which causes a healthy spark as they make contact. They are a repairable item in itself.

Ok, if I understand what you are saying, I would need to take the solenoid apart to verify? A friend said I may need to clean the brushes is that what you are speaking of?
 
Ok, if I understand what you are saying, I would need to take the solenoid apart to verify? A friend said I may need to clean the brushes is that what you are speaking of?

No, The brushes are another part of the starter, The solenoid sits piggy back on top of the starter. If you take it apart and clean or replace the contact disc you will be good to go
 
HD91FLHT011.gif
Here is a picture of the starter parts
ORDER

NO. PART NO. ELECTRICAL - STARTER ASSEMBLY
DESCRIPTION FXSTC SOFTAIL CUSTOM
91BK


1 925 SCREW, COVER 1 0.99 0.99
2 928 BOLT, STARTER 2 0.49 0.49
3 929 SCREW WITH O-RING 2 1.00 0.99
4 3403 NUT, FLANGE 1 1.99 1.49
5 3559 BOLT, STARTER 2 8.49 6.99
6 4325 SCREW 1 5.49 4.99
6A 4326A SCREW 2 0.99 0.99
7 6217 WASHER 1
7A 7041 LOCKWASHER 2 0.99 0.49
8 7838 NUT, KEPS 2 0.99 0.49
9 8871 BALL BEARING 1 18.00 14.99
10 8879 BALL 1 0.49 0.49
11 8883 BALL BEARING 1 18.00 14.99
12 9077 CLUTCH ROLLER 5 1.99 1.49
13 11116 O-RING 1 2.00 1.99
14 11182 RETAINING RING 1 0.99 0.49
15 11183 RETAINING RING 1 0.99 0.49
16 31342-90 PINION GEAR 1 91.49 75.99
17 31430-90 WASHER, THRUST 1 3.49 2.99
18 31510-90 HOUSING, STARTER 1 57.00 47.49
19 31514-90 YOKE ASSEMBLY, STARTER 1 157.00 130.49
20 31515-90 ARMATURE ASSEMBLY 1 146.00 121.49
21 31516-90 CLUTCH ASSEMBLY, STARTER 1 143.00 118.99
21 31517-90 SWITCH ASSEMBLY, MAGNETIC WITH HOUSING, #7, 30, 36, & 39 1
22 31518-90 BRUSH HOLDER ASSEMBLY 1 85.00 70.99
23 31519-90 FRAME, STARTER END 1 20.00 16.99
24 31525-90 IDLER GEAR 1 14.99 12.49
25 31527-90 BRACKET, COVER 1 16.49 13.49
26 31528-90 COVER (BLACK) 20.00 16.99
26 31535-91 COVER (CHROME) 1 18.99 15.99
27 31530-90 RETAINER, IDLER GEAR 1 0.99 0.99
28 31548-90 COUPLING 1 22.99 19.49
28 31553-90 STARTER, COMPLETE 1 350.49 290.99
29 31600-90 SPRING, RETURN 1 1.99 1.49
30 31604-91 STARTER REPAIR KIT 1 57.49 47.49
31 31660-90 DRAIN VENT 1 1.99 1.49
32 31661-90 SPRING, BRUSH 4
33 31662-90 BOOT, INSULATING 1 4.99 3.99
34 31663-90 CLUTCH, STARTER 1
35 31664-90 SHAFT 1 37.00 30.99
36 31688-90 COVER, SOLENOID 1 4.49 3.99
37 31689-90 BOLT WITH WASHER 3 1.99 1.49
38 31692-90 SPRING 1 1.99 1.49
39 31693-90 CLIP, CABLE 1
40 31695-90 O-RING 2 2.00 1.99
41 33126-90 LOCKPLATE 1 1.99 1.49
42 33127-90 SHAFT, EXTENSION 1 155.00 128.99
43 33340-90 O-RING 1 0.99 0.99
44 33449-90 SPRING, PINION GEAR 1 2.49 1.99
45 60647-90 COUPLING Here are the part numbers for the schematic
 
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Great help, still no luck. I believe there is a short circuit somewhere but I am unable to diagnose it. Replacing the harness now....... $400 later hope this works.......
 
If you go back to my post #17 it will tell you how to determine which wire has the short/ground. You can then tell where your problems is. There are 2 or 3 harnesses on the bike,Main,Interconnect and possible lighting. Which one are you replacing? A complete harness or partial? I would find the culprit first but that's my curious side.
tourbox
 
Thanks, I followed your instructions, but at this point I just don't have the patience to deal with it. What I have discovered through my diagnostics is that the whole harness from from to back has issues. So 100% of it is getting replaced, I for one have changed handlebar riser combos 3 times, painted it once so all sheet metal came off which required taillight changes and the fact that I have repaired the wires to the coil twice now. Oh and by the way the bike is at least 23 years old.
 
Well sounds like you have a good plan. If you have had to replace/repair that much wiring maybe it is time to do total replacement. Good luck with it and take your time. Keep us posted and let us know how it comes out.
tourbox
 
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