Question about 2003 Harley Davidson FXSTDI Softail Deuce

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Starting problem S&S 96 CI engine

I have a 2006 Saxon Firestorm, with an S&S 96 CI engine. About a month ago I was out for a ride. I parked the bike and when I went to start it, the starter just clicked. It started with no problem before the ride so I figured the starter was hung up. I kept intermittently pressing the starter button when I noticed the wire from the battery started to smoke and the battery terminal had started to melt. I called my wife to meet me and I had no choice but to jump start the bike with the car. When I got home I threw the charger on the battery and let it charge. I rode a few more times and now I'm getting just a click again when I go to start it. Again, I checked the battery, and even put the charger on. Fully charged it will not start. Any ideas what I can do to narrow down the problem?

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  • acviper Dec 31, 2008

    Ok, I checked everything that icasair said, and all wiring was good. I then checked the solenoid as topfuelhd said, and when I took the cover off the back it smelled like it was burned. I also seen that the post (where the wire that goes from the solenoid to the starter) the plastic piece was melted. Where do I buy a rebuild kit from?

    Also, I want to thank both of you for responding and helping so quickly!

  • acviper Dec 31, 2008

    First I want to thank both of you for answering so quickly. It turned out to be the solenoid. When I pulled the cover off it smelled like it was burned. The plastic was melted on the post that attaches the short wire from the starter. Is that part of the rebuild kit? By the way, where can I buy a rebuild kit from?

    Thank you again,

  • acviper Jan 03, 2009

    I rebuilt the solenoid and everything is working great! Thank you!

  • ian stalker May 11, 2010

    hi you havent mentioned wether you repaired the damaged cable and crimp? if not i would do this first you may find that the cable damage goes a lot further than you migt think! next check continuity of your starter cables with a multimeter,you should have very little resistance,this should be done with battery disconnected

    2/approx 90%of elec faults are due to faulty/earths

    please notify me if any of the above fails to help

    cheers ian

  • Anonymous Mar 19, 2014

    Lights are bright and battery seems fully charged but has a difficult time atarting.


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Sounds like the starter solonoid is not working properly if the batt cable got hot enough to smoke that says the batt, is ok and it is ok to jump with car, the solonoid is making the clicking noise and a real hot batt sometimes will make it work, the repair is simple and cheap if you are talented just get a solonoid repair kit three screws 5 min, and you are RIDEING.

Posted on Dec 31, 2008

  • Tom Diffin Jan 01, 2009

    check your local hd shop or online,n have had great luck with in sanduskie ohio


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