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techtalk:ih:engctl02 [2020/02/06 17:59] – [Solenoids] hippysmacktechtalk:ih:engctl02 [2023/12/31 18:18] (current) – hippysmack
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 Reference these threads:\\ Reference these threads:\\
-http://xlforum.net/forums/showthread.php?t=1521782 - Dr. Dick Post#4 quoted above\\ +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/140324-prestolite-hitachi-help?t=1521782 - Dr. Dick Post#4 quoted above\\ 
-http://xlforum.net/forums/showthread.php?t=1715008\\ +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/159854-starter-motors?t=1715008\\ 
-http://xlforum.net/forums/showthread.php?t=1752598\\+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/163098-starter-pipe-clearance?t=1752598\\
  
  
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 The 1981-later starters are the same Nippon Denso version as used on the Evolution model engines. The 1981-later starters are the same Nippon Denso version as used on the Evolution model engines.
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 For additonal information, see the [[techtalk:evo:engctl02|Evo Section - Starter/Solenoid]] For additonal information, see the [[techtalk:evo:engctl02|Evo Section - Starter/Solenoid]]
  
-|  Prestolite Starter. ((photos by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27))  ||+|  Prestolite Starter. ((photos by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27))  ||
 |{{:techtalk:ih:engctl:prestolite_starter_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:prestolite_starter_11_by_sifty.jpg?direct&300|}}| |{{:techtalk:ih:engctl:prestolite_starter_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:prestolite_starter_11_by_sifty.jpg?direct&300|}}|
 +
 +|  74-E76 Hitachi starter. ((photo by needspeed of the XLFORUM))  |
 +|{{:techtalk:ih:engctl:74-e76_starter_by_needspeed.jpg?direct&300|}}|
  
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 ====== Solenoid ====== ====== Solenoid ======
  
-A typical well-made solenoid as two windings connected to the small terminal. ((Oldwrench of the XLFORUM http://xlforum.net/forums/showthread.php?t=522413&page=2)) \\ +{{ :techtalk:ih:engctl:72-xlh-startersolenoid-operation.jpg?320|}} 
-One coil goes to solenoid case ground and the other goes to the big starter lead. \\ +A typical well-made solenoid as two windings connected to the small terminal. ((Oldwrench of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/74579-what-would-cause-the-solenoid-to-be-very-very-hot/page2?t=522413&page=2)) \\ 
-When you hit the starter button, battery voltage goes into the solenoid, through the 'PULL IN' windings to case ground, and that pulls in the plunger. \\ +One coil (HOLD-IN) goes to solenoid case ground and the other (PULL-IN) goes to a big terminal (starter lead).\\ 
-When the plunger pulls in, it brings the contact disc in contact with the big battery and starter terminals. \\ +When you hit the starter button, battery voltage goes thru the starter relay into the solenoid small terminal,\\ 
-When that disc connects with the starter terminal, it shorts out the PULL IN windings and applies voltage to the HOLD IN windings to reduce drain on the battery. \\ +·· then goes thru the 'PULL-IN' windings (which are grounded thru the starter motor) and thru\\ 
-If the battery cable is connected to the starter terminal of the solenoid, then the hold in windings will be conducting current. \\ +·· the 'HOLD-IN' windings (to the case ground).\\ 
-That current isn't strong enough to allow the HOLD IN windings to pull in the plunger but the current flow is enough to make the solenoid get really hot. \\ +**When these coils are activated together, they pull the plunger in.** 
-And if not disconnected, it will burn both the PULL IN windings and the HOLD IN windings because they are wound together inside the solenoid.+ 
 +When the plunger pulls in, it brings the large contact disc in contact with the big battery and starter terminals. \\ 
 +When that disc connects with the starter terminal, it bypasses the PULL IN windings, while the small terminal\\ 
 +·· continues supplying power to the HOLD IN windings. \\ 
 + 
 +**Make sure that your connections are to the proper large terminals!** 
 + 
 +**IT IS IMPORTANT** that you use the __**Large Long** Terminal to connect to the Battery__ and the __**Large Short** Terminal to connect to the Starter Motor__. If the Large Terminals of your solenoid are not one Long & one Short, use a multimeter or test light to bench test which Large Terminal has some continuity to the Small Terminal. Whichever Large Terminal has some continuity to the Small Terminal is the one that is connected to the Internal PULL-IN Coil and is the one to be connected to the Starter Motor. 
 + 
 +If the large terminal connections are swapped, with the battery cable connected to the output starter terminal of the solenoid, then the internal windings will be constantly conducting current. \\ 
 +That current isn't strong enough to actually pull in the plunger but the current flow is enough to make the solenoid get really hot. \\ 
 +If left this way, and not disconnected, it will eventually burn out either/both the PULL-IN windings and the HOLD-IN windings because they are wound together inside the solenoid.\\
 So you don't want to hook up the battery to the terminal used for the starter. \\ So you don't want to hook up the battery to the terminal used for the starter. \\
-The solenoid will still work at first, but left connected it will burn out either or both of the windings because the HOLD IN windings are constantly conducting. \\+The solenoid will still work at first, but left connected it will burn out either or both of the windings because the windings are constantly conducting. \\
 Using an ohm meter would give really confusing readings because you'd see continuity to both case ground and the starter terminal from the solenoid windings connection. Using an ohm meter would give really confusing readings because you'd see continuity to both case ground and the starter terminal from the solenoid windings connection.
  
-67 and Up XLH Starter solenoid (71469-65) \\ +\\ 
-Below, the 1/4" solenoid mounting threads were stripped (nut on the top bolt) so they were tapped out for 8mm cap screws. ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27)) \\+ 
 +**67 and Up XLH Starter solenoid (71469-65)**\\ 
 +Below, the 1/4" solenoid mounting threads were stripped (nut on the top bolt) so they were tapped out for 8mm cap screws. ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27)) \\
 8mm x 1.25 threads have almost exactly the same thread pitch as the original 1/4" thread. \\ 8mm x 1.25 threads have almost exactly the same thread pitch as the original 1/4" thread. \\
-Then the mounting bracket and and spacer were drilled 8mm and the solenoid was installed using allen head cap screws and spring washers. \\+Then the mounting bracket and and spacer were drilled 8mm and the solenoid was installed using allen head cap screws and spring washers.
  
-|  Starter solenoid (71469-65) ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=27))  |||+|  Starter solenoid (71469-65) ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page27?t=1592463&page=27))  |||
 |{{:techtalk:ih:engctl:solenoid_switch_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_2_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_3_by_sifty.jpg?direct&300|}}| |{{:techtalk:ih:engctl:solenoid_switch_1_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_2_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:engctl:solenoid_switch_3_by_sifty.jpg?direct&300|}}|
  
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 ===== Check Solenoid Cover for Conductivity ===== ===== Check Solenoid Cover for Conductivity =====

Trace: • 3 • term-0 • EVO: Engine Control