Harley-Davidson Starter Solenoid Repair Instructions

Written by danyel bierly
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Starter solenoid replacement may be necessary if your Harley-Davidson motorcycle is having problems starting up. One sign of this is if you hear a rapid clicking sound when you try to start your motorcycle, but the bike ultimately fails to start. After ruling out the battery, the solenoid is a good next guess. Repair kits are available locally and online and include all necessary parts to replace the starter solenoid in your own garage.

Skill level:
Moderately Challenging

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Things you need

  • 3/8-inch Socket wrench
  • Wire cutter
  • Starter solenoid repair kit
  • Solder gun
  • Solder wire

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  1. 1

    Disconnect the battery by removing the ground wire also known as the minus wire.

  2. 2

    Remove all of the bolts and washers from the top of the starter solenoid using the socket wrench. Do not discard these bolts and washers as you will need them to install the new starter solenoid.

  3. 3

    Gently lift up the starter solenoid cap and locate the two wires connected to the large and small copper bolt. Snip the wires as close to the large copper bolt that they are attached to with the wire cutter. Throw away the old copper bolt and wire that is attached to it.

  4. 4

    Remove the old plunger in the middle of the starter solenoid by gently pulling it directly out with your fingers. Place the new plunger from your solenoid repair kit into the starter.

  5. 5

    Plug in the solder gun and solder the new copper bolt to the end of the wire sticking out of the solenoid. Add solder wire by gently touching the solder wire to the copper bolt and place the hot tip of the solder gun to the wire. Repeat this step for both wires taking care not to solder the wire to the plunger.

  6. 6

    Inspect the starter solenoid for any other worn parts and replace with new parts from the repair kit. Place the large copper bolts into the holes of the new starter cap and seat the cap onto the starter. Re-install the bolts and washers for the cap.

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