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  #1 (permalink)  
Old 10-21-2009, 11:42 AM
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Angry Attempted first start up, and having a huge issue - DETAILS INSIDE

Well, attempted to start my bike for the first time, and it turned over a few revolutions. I accidentally let go of the enrichener post, and the engine stalled.

Now what happens, is that when I try to start it, it gets to one of the compression strokes (and I have the built-in compression releases pushed down), and the jackshaft gets stuck on the clutch hub (BDL TF-2000 primary drive) and makes a loud clacking sound as if the starter motor is turning but the jackshaft isn't.

I tested the battery and it looks like it's at 9V but I'm using an OLD battery tester (that has a needle, not a digital readout), and there's no 12V setting, so I have to use the 50V setting and try to figure out how many volts the battery is charged.

I have a battery tender on it right now, and I'm going to try again once it's fully charged.

If I have to take the starter out to change the BDL jackshaft to a different kind, it's going to be a BITCH.....The starter doesn't come out very easily unless you loosen the rear belt tension and with the rear fender on, it's going to be a HUGE issue.

Any idea what that clacking (it's like clack-clack-clack-clack-clack) noise is as I turn the key to "Start" and why the jackshaft won't turn after 1/2 revolution?


Using 350CCA Braille battery
1.4Kw starter with BDL jackshaft
BDL TF-2000 primary belt drive
Ultima 127" engine
2-gauge Sumax battery cable from negative battery post to starter bolt
2-gauge Sumax battery cable from positive battery post to start solenoid post
Everything else is grounded directly to the negative post on the battery except for the voltage regulator wire, which goes to a 40-amp inline breaker to the positive post on the battery.

Last edited by MikeV019; 10-21-2009 at 12:01 PM..
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  #2 (permalink)  
Old 10-21-2009, 11:53 AM
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9 volts is not going to cut it.

Last edited by muff; 10-21-2009 at 12:02 PM..
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  #3 (permalink)  
Old 10-21-2009, 11:57 AM
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Check all battery Connections
Jackshaft assembly
Try to get the battery up to 12.5 to 13v
If it is single fire make sure timing is correct and plug wires are not crossed
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  #4 (permalink)  
Old 10-21-2009, 12:01 PM
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Quote:
Originally Posted by muff View Post
9 volts in not going to cut it.
I'm charging it right now, and hopefully it'll work when I try again in a few hours.
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  #5 (permalink)  
Old 10-21-2009, 12:02 PM
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Quote:
Originally Posted by muff View Post
Check all battery Connections
Jackshaft assembly
Try to get the battery up to 12.5 to 13v
If it is single fire make sure timing is correct and plug wires are not crossed
Everything's tight and secure on the battery, timing is set according to Ultima's specs, and plug wires are not crossed.
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  #6 (permalink)  
Old 10-21-2009, 03:28 PM
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Sounds like not enough current is being supplied to the starter. That first start may have drained much of the capacity of that battery. So now, you're not providing enough voltage and current. The clack-clack-clack sound could be the solenoid plunger bouncing back and forth because there's not enough power to keep it activated. (Could also be due to using too small gauge a wire to the solenoid spade terminal. 10 gauge is plenty good enough. 12 gauge might still cut it.

Easy to determine starter condition. Remove the bike battery. Run some good jumper cables from a good car or truck battery direct to those cables--do not have donor vehicle motor running--and hit the start button. It should start the bike.
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  #7 (permalink)  
Old 10-21-2009, 03:54 PM
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Quote:
Originally Posted by CENJIM View Post
Sounds like not enough current is being supplied to the starter. That first start may have drained much of the capacity of that battery. So now, you're not providing enough voltage and current. The clack-clack-clack sound could be the solenoid plunger bouncing back and forth because there's not enough power to keep it activated. (Could also be due to using too small gauge a wire to the solenoid spade terminal. 10 gauge is plenty good enough. 12 gauge might still cut it.

Easy to determine starter condition. Remove the bike battery. Run some good jumper cables from a good car or truck battery direct to those cables--do not have donor vehicle motor running--and hit the start button. It should start the bike.
Mr. Scary also suggested the jumper cable idea, and it worked perfectly. The bike FINALLY runs!
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  #8 (permalink)  
Old 10-21-2009, 04:00 PM
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Ha Ha Jim...Beat ya to it. LOL LOL
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  #9 (permalink)  
Old 10-22-2009, 06:30 AM
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some behind the scenes shenanigans, Mr Scary?

LOL!

takes an Italian to beat an Italian!
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The life of the land is perpetuated in righteousness.

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  #10 (permalink)  
Old 10-22-2009, 09:30 AM
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the jackshaft could get stuck on the ring gear and not spring back, could this be it.
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  #11 (permalink)  
Old 10-22-2009, 11:02 AM
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Quote:
Originally Posted by CENJIM View Post
Sounds like not enough current is being supplied to the starter. That first start may have drained much of the capacity of that battery. So now, you're not providing enough voltage and current. The clack-clack-clack sound could be the solenoid plunger bouncing back and forth because there's not enough power to keep it activated. (Could also be due to using too small gauge a wire to the solenoid spade terminal. 10 gauge is plenty good enough. 12 gauge might still cut it.

Easy to determine starter condition. Remove the bike battery. Run some good jumper cables from a good car or truck battery direct to those cables--do not have donor vehicle motor running--and hit the start button. It should start the bike.
Or you could run two 16 gauge wires to the solenoid. I'm doing it that way and it works well. The dual 16 gauge wire method also works when wiring the headlight.
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  #12 (permalink)  
Old 10-22-2009, 11:18 AM
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I have the same motor same battery and a 3" BLD not the 2" otherwise I have even the same starter and had the same issue it was the shitty jackshaft that came with the BDL. The jackshaft wasnt engauging the ring gear correclty and it ended up destroying the ring gear. The fix was a new jackshaft from Spyke it is a 2 piece design. I cant remember the name I have the information at home if you need it.....
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  #13 (permalink)  
Old 10-22-2009, 11:39 AM
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Bulletproof jackshaft, if that's what you're referring to.
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  #14 (permalink)  
Old 10-22-2009, 11:44 AM
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Quote:
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Bulletproof jackshaft, if that's what you're referring to.
Thats the one.....
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