It's started, bits fell off & won't start (help)

[Adam 105th sportster]

The bike kept backfiring through the exhaust on the way home yesterday & I discovered the 2 bolts holding the rear exhaust manifold flange missing! Replaced those and this morning it won't start! Can't see it's related but hey these are H/D's ;-)

Wife noticed 2 orange sparks by my right leg when I hit the starter button this morning. It half turned for about a second then stopped & that was it. I have 5.4 volts on the batt' live to the engine casing but absolutely nothing on the light panel when I turn the key to hot.

Any pointers or idea's on where to start looking? This is my first Harley so it's not all that familiar a layout. I've had a V&H fuel pack fitted about a month ago & up until this morning the bike was 100% reliable. Really wanted to take it to the Hot Rod drags in Stratford this weekend.

[Mantis]

I'm no expert, but sounds to me like an electrical fault, possible loose connection, bad earth, blown fuses, does the starter click?, electrics are really my bad point, but for what its worth.

[OrangeR]

Originally Posted by Adam 105th sportster

The bike kept backfiring through the exhaust on the way home yesterday & I discovered the 2 bolts holding the rear exhaust manifold flange missing! Replaced those and this morning it won't start!

Do you really mean 2 bolts? These are secured by 2 studs and nuts. You may need to replace the gasket to stop any leaks. Be careful when tightening the nuts up they only go to 120in-lb (10ft-lb). Also check the front ones aren't lose.

Cheers,

OR.......

[Adam 105th sportster]

Yea I meant studs not bolts. Thanks for the torque setting, I'll back it off a little!

Yea something's definately gone fubar on it. Just about to check the fuses and see if one of those had blown but judging from what the wife saw I suspect it will happen again as I think somethings amis. Update in a mo!

[Mantis]

Originally Posted by Adam 105th sportster

Yea I meant studs not bolts. Thanks for the torque setting, I'll back it off a little!

Yea something's definately gone fubar on it. Just about to check the fuses and see if one of those had blown but judging from what the wife saw I suspect it will happen again as I think somethings amis. Update in a mo!

Doesnt matter to much you just want to know the circuits not broken ( electrics working ) if so then its going to make fault finding much easier.

check connections before starting again.

[Adam 105th sportster]

Bugger, all fuses look good so I either have an open circuit somewhere in a wire or a component failure. Any guesses on what the sparks could have been?

[Mantis]

Originally Posted by Adam 105th sportster

Bugger, all fuses look good so I either have an open circuit somewhere in a wire or a component failure. Any guesses on what the sparks could have been?

It sounds to me like a loose wire or something touching or not located properly. Did you check the bulbs of the components or connection, is the ignition working, do the lights ( main beam )come on. When you rode the bike did they lights go really bright and dull etc.

Seriously I hope someone comes along with a little more knowledge than me as I'm not the best person to ask on electrics.

[kiwidave]

Is negative battery connection TIGHT at the terminal?

Having said that,and having re-read your post.....

Battery should show 12.8V or thereabouts across its terminals with ignition OFF.

If it drops below 12V with ignition ON, battery will not hold a load. And, obviously it will not start.

If that is the case, I would recharge the battery overnight, see what happens with key test (poor man's load test) tomorrow. If after a 24hr trickle charge the voltage still sinks below 12.0V the moment you turn the ignition on...the battery will be irreparably damaged. And then you need to find out why.....

[Mantis]

I was thinking that the batter should be reading 12.5-13volts.

Batteries can cause weird things to happen when its dieing.

[Adam 105th sportster]

Hey don't knock yourself your helping me & I appreciate it. I work as a signal tester on the underground but it's like talking to a Russian in Chineese trying to apply that to auto electrics.

Ok, the ignition key got all the panel lights up this morning then it kicked over once and died without actually starting. Wife said she saw a spark jump out near my right leg (& she was 20' away so it must have been a decent one) and now the whole thing is dead. Nothing on the panel (next to the speedo) with the key in 'hot' & no headlights on. Basically I have 5.5volts on the battery & thats about it, nothing anywhere else.