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#1: Re-intro and a question

Posted on 2006-07-23 17:22:19 by sprglde77

Hi all, I haven't been here in quite a while, been way too busy. I'd
like to buy a round and ask for a little help. After 30 years of ridin
my FXE and a few Bonnie's I finally got me an EVO. I know my new bike
is 14 years old but it's way new to me an she's a beauty, had only 20 k

on her when I got it. It's a 92 Classic (FLHTC) and I'm really enjoying

being able to do some long distance ridin (3-400 mi.) in a day (again)
and not needing a days rest, new kidneys an a couple fillings. Anyways,

this bike's got an electrical problem that's a little troublesome. The
starter doesn't work sometimes. Also when this occurs the controls for
the radio on the right side don't work either. I have to jump it
between the exciter and the hot lead to the starter motor, and it
starts just fine. I've had the fairing off several times and then
everything works. Now I wish the friggin thing would just stop workin
but it won't. So I put it back together and then it stops workin
again???? The stealership says for a thousand $ they'll put a new
starter and relay in even after I told them about the radio thing. A
friend of mine's got a 91 bagger that does the same thing. He put in a
400$ starter and relay and it still does the same thing??? I know this
cannot be limited to just our 2 bikes so I'm hoping someones got a hot
lead (pun intended) for me/us. We know it's a bad connection or ground
but where??? Like I said when I'm in there rootin around it starts
working and it 's all good and as ya'll know ya can't fix it if it's
working.... I can't even locate the grounds up there there's so much
wire in here. I'm hoping someone's fixed this problem before and can
point me in the right direction. I'll be sittin at the table over here
waitin. Thanks, Marley

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#2: Re: Re-intro and a question

Posted on 2006-07-23 19:30:41 by Phil Boutros

marley &lt;<a href="mailto:sprglde77&#64;msn.com" target="_blank">sprglde77&#64;msn.com</a>&gt; wrote:
&gt; Hi all, I haven't been here in quite a while, been way too busy. I'd
&gt; like to buy a round and ask for a little help.

We heard you the first couple of times (hehehe)...

&gt; It's a 92 Classic (FLHTC) and I'm really enjoying
&gt; being able to do some long distance ridin (3-400 mi.) in a day (again)
&gt; and not needing a days rest, new kidneys an a couple fillings.

Congrats on the new ride.

&gt; this bike's got an electrical problem that's a little troublesome. The
&gt; starter doesn't work sometimes. Also when this occurs the controls for
&gt; the radio on the right side don't work either. I have to jump it
&gt; between the exciter and the hot lead to the starter motor, and it
&gt; starts just fine.

OK...So obviously, the starter and solenoid are fine (for
reference below).

&gt; I've had the fairing off several times and then
&gt; everything works. Now I wish the friggin thing would just stop workin
&gt; but it won't. So I put it back together and then it stops workin
&gt; again????

OK...Sounds very much like a wire is getting pinched or pulled
when the outer fairing is put back on.

&gt; The stealership says for a thousand $ they'll put a new
&gt; starter and relay in even after I told them about the radio thing.

This dealership is full of either: A) Thieving bastards B)
Incompetent technicians and/or service writers C) Both.

How are they going to explain it when they change the starter
for big bucks and it *still* won't start (because the starter
obviously isn't the problem, see above).

Could be the relay, I guess. That's why multimeters were
invented, though. Find a shop that is experienced in *proper*,
*systematic* electrical diagnostics. Measure the voltage at the
proper relay connections (hot side, ground side, switched side, output
side). That'll tell you if it's getting signal from the start button.

Speaking of which, measure voltage at that switch too.

However, everything points to a wire getting pinched or pulled
when the fairing gets put back on. This is good and bad. It's good
because it's an easy fix. It's bad because it may be a PITA to find.
Time for the ol' wiggle test, look for frayed wires, etc...

&gt; A
&gt; friend of mine's got a 91 bagger that does the same thing. He put in a
&gt; 400$ starter and relay and it still does the same thing???

See above. The shop that would sell a new starter when
simple diagnostics obviously indicate that the starter is fine is one
that is out to rape customers.

&gt; We know it's a bad connection or ground
&gt; but where???

In the fairing is my guess!

&gt; Like I said when I'm in there rootin around it starts
&gt; working and it 's all good and as ya'll know ya can't fix it if it's
&gt; working.... I can't even locate the grounds up there there's so much
&gt; wire in here.

Welcome to the joys of a '92 bagger. Your first mission is to
clean up that spaghetti wiring in there. That'll require lots of
tie-wraps and time.

Concentrate on the wires going to the right switch housing,
and the associated connectors. Sounds like the kill switch wiring
works, since the bike starts when you jump it. Get a schematic, and
see if the start button and radio controls share a common hot lead
somewhere. Work your way through the schematic.

Electrical diagnostics for those years is very limited in the
manual, and sometimes even points you the wrong way. I find that
working through the schematic and checking connections and voltages at
key points helps a lot.

Obviously, pay particular attention to wires near metal
brackets that could get pushed on them when the outer fairing is put
back on. Or wires that are fairly taught and could get pulled further
when the fairing is put back on.

&gt; I'm hoping someone's fixed this problem before and can
&gt; point me in the right direction.

That's the best I can do from over here. Schematics.
Multimeter. Wiggle Test. All of those are your friends.



Phil
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