series parallel switch rebuild (6 Viewers)

[PHIL O]

has anyone rebuilt their series parallel solenoid? it looks sealed from factory, but i am guessing there is a way to open it. or could anyone post a link to a thread discussing this. search has not been helping since the switch comes by many names and the results are limited to what i call the series parallel switch. i am suspecting this is the culprit of my no start problem. one day i tried to strat the hdj81 but only a click from a relay. i ruled out the starter since i have rebuilt it recently. then i plugged in a jump starter powerbank on the driver's side battery and was able to start it. the next time, i plugged the jump starter on the other battery but couldnt get it to start. it only starts when i plug the jump starter to the driver's side battery making me think that the ignition switch doesnt connect both in series when i turn the key. thank you gents for your inputs

 

[Squash]

Have you load test the fusible link. These will light up a test light, but not enough juice for the start circuit.
Line runs from the PS battery and under the windshield washer.
I assume that both batteries are fully charged and all connectors are tight?
You'd be surprised how a loose battery post will screw up the start circuit.

 

[HDJ80L]

You are talking about the 12-24V voltage converter relay in the engine bay right? That component is not designed to be opened up and serviced, if it's broken you'd have to find a replacement or look for another solution like 12V starter conversion. There's a detailed troubleshooting section for the voltage converter relay in the engine manual you can follow to test the component itself. But since you mention that a powerbank helps with starting it sounds more like its a battery or battery connection issue. Both batteries need to be healthy in order for the 24V starting system to work properly.