My 1986 1200 DIES!

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sidejack

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Jun 14, 2023
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Situation:
1. Battery good; cranks 220A
2. Accessory port works -- powers added stuff
3. Turning ignition key to "ON"; lights alive/etc
4. Battery voltage reads 12.6v
5. Push starter button; EVERYTHING DIES; battery goes to Zero even when starter button released and NO "click" of starter, and 30a main fuse still good

So far:
1. Replaced Starter Relay Switch (original switch had nasty connections)
2. Cleaned contacts on starter button; opens/closes correctly
3. Disconnected battery; reconnect; voltage may or may not go back to 12.x volts. If 12.x volts and repeat of steps results in same.

Starter Motor maybe? I'm stuck.
(Good news; got 2 other bikes to keep me on the road -- but, grandkids aren't getting a ride for awhile)

Any advice appreciated .....Sidejack
 
Connections to starter motor (heavy curre nt wires can get corrosion and poor continuity inside the crimped-on end connectors. Solenoids may (or may not) click but burnedinternal contacts not make contact. A carefully connected automotive jumper cable from + post tapped on starter post bypasses most of this. Wear safety glasses and have no fuel or vapors present as this can produce sparks with molten copper.
 
battery, circuit breaker, bad ground. disconnect cable from starter to prove rest of circuit as a fast test. then do PIDJPONES test while start cable still disconnected as quick test for starter. poboy redneck method.......disregard if you have meters, expreience,etc
 
pidjones said:
Connections to starter motor (heavy curre nt wires can get corrosion and poor continuity inside the crimped-on end connectors. Solenoids may (or may not) click but burnedinternal contacts not make contact. A carefully connected automotive jumper cable from + post tapped on starter post bypasses most of this. Wear safety glasses and have no fuel or vapors present as this can produce sparks with molten copper.
Click to expand...
I'll try that this week --
 
sidejack said:
Battery PERFECT -- wish that was the answer
Click to expand...
DId you have it load tested? I have same symptoms and it was a bad AGM battery. One morning started fine, next nothing. Not like a normal lead acid where it normally gives warning af failure coming.
 
If your voltage measured at the battery goes to zero and there isnt smoke somewhere (dead short) I'd suspect battery. AGM batteries can fail like that. Only a load test will confirm. Most auto parts stores can do that for you.
 
sidejack said:
I'll try that this week --
Click to expand...
Test as you suggested confirmed that the starter motor IS the problem --
Bypassing everything, and connecting the battery direct to the motor -- battery shorted; starter did nothing.
ALSO, with the starter motor disconnected from the starter relay -- when the starter button is pushed, lights stayed on and the starter relay "clicked"
SO, pretty sure I'll be buying a starter motor.
Thanks for the assistance.....jack
 
pidjones said:
Pull it off and check. Sometimes simple things such as dirty commutator, stuck or used-up brushes.
Click to expand...
yep, the gears were stuck in mine. on another. it was the brushes coroded with some black stuff. in both cases, it was only time involved.........no momey spent.
 
If there is an alternator repair shop close by, look into having the starter rebuilt. Only takes the shop a few hours and it may be less expensive than a new aftermarket non-OEM starter motor. Battery, load test only or a complete load test and internal health check. A bad battery cell, or one that is failing is not the friend of the electrical system.
 
I have a completely rebuilt GL1100 starter sitting on the shelf. Problem is, I cannot remember if the 1100 and 1200 starters are interchangeable.

1100 Starter Rebuild 002.jpg



1100 Starter Rebuild 011.jpg
 
Rednaxs60 said:
If there is an alternator repair shop close by, look into having the starter rebuilt. Only takes the shop a few hours and it may be less expensive than a new aftermarket non-OEM starter motor. Battery, load test only or a complete load test and internal health check. A bad battery cell, or one that is failing is not the friend of the electrical system.
Click to expand...
My 87 Interstate would start cold, but not hot., even with a jump, so I looked at the starter. The brushes were half the original length, and carbon dust was everywhere. I went to an automotive electrical shop and bought matching brushes for $10. I cleaned, regreased and reassembled the starter. Works fine now.
 

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