How to Repair a Harley Starter

The solenoid on a starter opens the electrical circuit to start an engine. When you turn a key on a vehicle to start the engine, the circuit is opened and electrical current flows from the battery to the solenoid on top of the starter. Sometimes the solenoid will stop working when terminals and plungers become worn, which prevents a complete circuit. It's not too difficult to replace a worn solenoid on a Harley-Davidson motorcycle, and you will avoid the expense of replacing the whole starter.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• 3/8-inch socket
• Wire cutter
• Soldering gun
• Solder wire
• Solenoid replacement kit

1. • 1

     Purchase a solenoid replacement kit from a Harley dealer. Choose a kit compatible with your motorcycle make and model. Disconnect the battery terminals to avoid electrical shock.

   • 2

     Remove the bolts on top of the starter that secure the solenoid using the 3/8-inch socket. Place all bolts, washers and nuts in a safe place. You will need them to reattach the solenoid to the top of the starter.

   • 3

     Lift the solenoid cap off the top of the starter. Be careful not to force the solenoid or to pull it. The solenoid is attached to the starter by a thick copper wire.

   • 4

     Cut the copper wire attached to the old solenoid using the wire cutters. Cut the wire close to the large copper bolt on the solenoid to preserve as much length of the wire as possible. Place the old solenoid cap into the trash or set it aside for recycling of the copper bolt attached to the cap. Leave the small bolt attached to the other wire on top of the starter.

   • 5

     Remove the old plunger in the center of the top of the starter. The plunger is a straight object with a disk near the top and a spring on both sides of the disk. Discard the old plunger and replace it with the new one provided in the solenoid repair kit.

   • 6

     Attach the wire that you cut to the new solenoid copper bolt. Use only enough solder to securely attach the wire. Too much solder may interfere with the plunger. Guide the small bolt through the other hole on the new solenoid.

   • 7

     Press the new solenoid cap into place. Reinstall the nuts, bolts and washers to hold the new starter solenoid in place. Reconnect the battery.

Tips & Warnings

• Familiarize yourself with the parts of the solenoid before beginning installation of a new starter solenoid.

• Always disconnect the battery when working on the electrical components of a motorcycle engine to avoid electrical shock.

• Use extreme caution when soldering wires. The tip of the soldering gun and molten solder can cause severe burns.