Locating Troubles

The starter motor is designed to be corrosion resistant and requires very little maintenance. However, to insure satisfactory operation, periodic inspection of brushes and commutator should be made. In the event starter motor fails to operate satisfactorily, the following checks should be made before removing motor for inspection:

1. Wiring

Make sure the mounting and wiring connections are tight and in good condition. The solenoid switch should be firmly mounted and all wiring connections should be clean and tight. Also inspect the connections to the battery and return circuit, as loose or dirty connections anywhere in the circuit will cause high resistance and reduced motor efficiency.

2. Battery

If the connections and wiring are found to be satisfactory, the battery should be checked to determine its state of charge (See Section 5J, "Charging Battery") . If the battery is charged and battery voltage is reaching the motor without any excessive losses in wiring or connections, the trouble may be attributed to either the engine or the starter motor itself.

3. Switches

If the battery is charged but there is no current flow to motor at all, trouble is probably in handlebar button switch, transmission cutout switch or the sole noid switch. This can be determined by by-passing each switch with a heavy jumper (Refer to wiring diagram, Section 5B). 4. Engine

Excessive friction in the engine from tight bearings or pistons or from heavy oil obviously makes engine harder to crank. However, if engine is known to be in normal condition and the rest of the starting system is satisfactory, the starter motor should be removed for further checking.

NOTE: Electrical tests to locate cause of starting system failures can be made using the Sun VAT-26 Tester and applicable Service Bulletins.

REMOVING STARTER MOTOR AND DRIVE SERVI-CAR (Fig. 5L-5)

Disconnect solenoid and battery cables from starter motor. On 1964-65 model, remove motor thru bolt nuts and lockwashers (1), securing motor (2), until it can be removed as an assembly from starter shaft housing and transmission top cover flange (3). Remove starter motor end support bracket (not shown). On 1966 and later models, unscrew motor thru bolts (4) from transmission cover (3A).

NOTE: Late 1966 mounting flange has 2 sets of holes for Delco Re my or Prestolite motor.

ELECTRA-GLIDE (Fig. 5L-6)

Disconnect solenoid cable from starter motor terminal. Remove attaching nuts and lockwashers (1) which fasten starter motor housing (3) to studs on chain housing. Remove starter motor end support plate (not shown) from transmission. It may be necessary to loosen and raise battery carrier to provide clearance. Remove starter motor (2) and starter shaft housing (3) from motorcycle as an assembly.

SPORTSTER (Fig. 5L-7)

Disconnect solenoid cable from starter motor terminal. Remove starter motor clamp bolt and lockwasher (1) from crankcase. Unscrew motor thru bolts (4) from starter shaft housing (3). Remove starter motor and clamp (2) as an assembly.

delco-remy starter motor service

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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