My 79 xlh sportster sat for some time,but after getting a new batterie, only the solenoid clicks, (ill admit i jerry rigged the starter for a quick test) symptoms became worse and worse, now to the point once bike is turned off. starter will sometimes keep spinning to the point the starters terminal glows RED hot, in a matter of seconds. now starter doesnt spin anyway, but even still when postitive lead is touched. again same ridiculous outcome.....short circuit somewhere?........

bad starter switch might be the issue. barely connecting. try jumping the switch or battery to starter directly to see. good luck

I would get new battery ,and check ground wires.

Two things to check:

1. there is a 4 pin black starter relay maybe 1" cube, usually under the seat, that goes bad. since they are impossible to get from Harley, go to JPcycles.com and get a new one. I have to replace mine every year or so.

2. Disconnect the battery. Open the Starter's attached solenoid cover. There is a copper bar that gets pitted. If it hasn't been done before, flip it over. Otherwise try to clean it up. Replacing would be a good idea if you could find one. Otherwise buy copper stock from Mcmaster-Carr and make one.

It ain't easy owning an old school Sportster... It's an adventure!

Turbocouch
76 XLCH 1000 and 81 XLH 1000

This is a possibility. The header says you're working on a 1979 XLH 1000cc Sportster. This is not a 250cc bike and it takes a good battery to start and engine of this size. I've never seen a CCA rating on the battery requirement in a service manual but it does say that the battery should be capable of at least 32 Ahr.

Good Luck
Steve

First off, take your battery out and have it tested at a local auto part house. Ask them to "load test" the battery. If its good, then your problem is probably in the starter solenoid.

Your 83 Sportster should have the Nippondenso type starter on it. Remove the five sided plate from the rear of the starter. It's held on by three 3mm screws. Remove the plate, the larger plunger, and the spring. Look inside the solenoid and you'll see two large copper contacts. Look at these contacts and see if they are burned. They should be smooth across the top. If they look like they've got a curved "step" burned into them, they need to be replaced. You can purchase a rebuild kit from most aftermarket dealers. The kit cost about $50 and you can usually install it without pulling the starter.

Good Luck
Steve

There's a quick test to see if your starter is the problem or something else is causing it. First, it's very important that your bike is in neutral to do this test. If not, the bike is going to lurch forward.

Remove the rubber cover over the end of your starter solenoid. Use and old screwdriver or something and short between the small terminal and the large terminal that the cable from your battery connects to. The starter should kick in and turn the engine over. If it does, the starter is good and your problem is electrical.

If it's electical, there are two places it could be. Underneath the battery tray, there is a starter relay. Again, the bike must be in neutral. Turn the ignition switch on and while holding the starter relay, push the starter button. Do you feel a click? If so, this confirms the wiring between the relay and start button is alright.

Now, you'll need a test light or a volt meter for the next check. On the small terminal of the starter solenoid. connect the test light or the Positive lead of a volt meter, the negative lead of the meter to a good ground. Put the meter function switch in DC volts. 20 volt range. Turn on the ignition and press the starter button. The test light should light up or the meter should read battery voltage. If it does not, your starter relay is bad. If it does, your solenoid needs a repair kit installed in it.

A repair kit is available from aftermarket sources. Most any bike shop can order them for you and they aren't expensive. Disconnect the battery and all the wires on the end on the solenoid. Remove the nuts that were under the wires on all three terminals. Take the two small screws out of either side of the solenoid end cap and remove the cap. Replace the cap with the new parts and the new cap. Be careful when tightening the two screws and the nuts on the terminals as the bakelite end cap cracks very easily. Just snug on the nuts and screws. Reconnect the wires and your starter should work.

If not, let me know.

Good Luck
steve

1997 HARLEY DAVIDSON SPORTSTER XLH 1200

STARTER REMOVAL
1. REMOVE LEFT SIDE COVER
2. REMOVE NEG. BATTERY CABLE FROM CRANKCASE TO PREVENT ACCIDENTAL STARTUP
3. REMOVE POSITIVE BATTERY CABLE
4. DRAIN TRANSMISSION FLUID (5/8" SOCKET)
5. REMOVE PRIMARY COVER (IF YOU'RE UNSURE OR IT'S BEEN AWHILE - PLEASE CONTACT - I CAN PROVIDE INFO)
6. REMOVE REAR EXHAUST
7. REMOVE 2 STARTER BOLTS (5/16" ALLEN)
8. REMOVE STARTER
9. REMOVE GASKET
10. SLIDE BOOT BACK AND DISCONNECT THE POSITIVE CABLE FROM BATTERY (12MM)
11. DISCONNECT STARTER SOLENOID POSITIVE LEAD TO STARTER
12. LOOSEN WIRE BAND NUTS 3/8" SOCKET

If anything you're unsure about or been awhile just comment below or reach out. The primary cover has a few quirks to get off - can go further with you if needed. All The Best, Justin Lee
17 South Industries, LLC

Ok, If you are absolutely sure the battery is good, there are several possibilites. If the battery is over a year old, take it to an automotive parts store and ask them if they can load test it. They'll usually do this at no charge.

If the battery is good, the first problem could be in the starter relay. Look at the end of the starter from the right side of the bike. You'll see a plate on the end that is roughly shaped like a pentagon. Just above that plate is a plug with a single wire. Unplug this wire and use either a test light or a digital volt ohm meter to check for voltage when you press the starter button. If you do NOT have voltage and the clicking you are hearing is coming from under the seat, you probably need a starter relay.

If you have 12 volts on that wire, you're problem is in the starter. Disconnect the negative cable from your battery. Now, take the three small screws out of the back of the starter that holds the pentagon shaped plate on. Underneath the plate is a plunger and a spring. Remove these parts and look at the copper contacts on either side of the solenoid and on the plunger. If they are burned badly, you need to replace them. You can get the parts through an aftermarket supplier and they are not very difficult to replace. Usually, it can be done without removing the starter. Simply replace the contacts and a new plunger comes with the parts kit. Reassemble the starter, reconnect the battery cable, and you should be ready to go.

Good Luck
Steve