Dreaded click question
Road Master
Joined: May 2009
Posts: 817
Likes: 1
From: N.E. Ohio
My click staterd the same way as dz1087s. Then after about a year it became more and more common. On my bike (1987 FLHTC) the rebuild kit wasn't to hard. You have to resolder a wire to the new contact end. It was short and britle. They also give you a little piece of steel rod to solder on the wire. I think it kind of a fail safe. it was a bitc* to get on, but as far as everything else it was easy.
Cruiser
Joined: Jan 2010
Posts: 135
Likes: 0
From: NW FL
Well, I finally got back and the first thing I did was go and buy the rebuild kit. I wasn't at all happy that the instructions called for removal of the starter. Since I did not want to tear into the primary case and remove the clutch to take the starter off, I just wound up loosening it so I could get about a 1/2 inch clearance beneath the solenoid. I managed to remove the bottom contacts that way, worked out pretty well but got a few hand cramps along the way.
The contacts were black with carbon and had actually had quite a bit cut away from them in 17 years of starting. Just before I changed it out, I tried to start it and it was acting as if my battery was dead, so I put the charger on it. Once it was fully charged, it started, but still sounded like the battery was low. After I had changed the contacts out - oh, boy! Sounded like I had a brand new starter! It was spinning a lot faster than before, I guess because it was getting alot more amperage through the solenoid contacts. Anyway, definitely a well spent 60 on the rebuild kit.
The contacts were black with carbon and had actually had quite a bit cut away from them in 17 years of starting. Just before I changed it out, I tried to start it and it was acting as if my battery was dead, so I put the charger on it. Once it was fully charged, it started, but still sounded like the battery was low. After I had changed the contacts out - oh, boy! Sounded like I had a brand new starter! It was spinning a lot faster than before, I guess because it was getting alot more amperage through the solenoid contacts. Anyway, definitely a well spent 60 on the rebuild kit.
Road Master
Joined: Aug 2010
Posts: 1,205
Likes: 18
From: SE Michigan
Jeez, I've got a '91 FLHS with I think the original solenoid contacts in it with almost 67K miles. It seems to start strong with no problems. Have the soleniod button installed also. How long should those contacts last?
Road Master
Joined: May 2009
Posts: 817
Likes: 1
From: N.E. Ohio
Mine started acting up around 78,000. It would do it once in a while. I cleaned all the connections and did the dual relay set up. it stopped for like 1 month. Then it started clicking again and just got worse. After I did the re-build I left the dual relay hooked up it can only help. I cant get a push button cover for my year.
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Seasoned HDF Member
Joined: Jun 2010
Posts: 9,332
Likes: 3,871
From: Upstate New York
My solenoid contacts lasted 17 years and 160,000 miles with an occasional cleaning until this year. They're now worn too far to get reliable contact. The positive contact is eroded to a fragile thin web, and you can see signs where the center washer has welded itself to the contact and broken again. I've been messing with the prospect of rebuilding the solenoid contacts, but, given the age of the entire starter, I might be better off replacing the entire motor.
I've had the push button cover for a few years, and it helps if the battery is weak, or you have a bad relay or switch, but as has been said, if the solenoid contacts are shot, it won't help.
I wish I had a kickstarter.
I've had the push button cover for a few years, and it helps if the battery is weak, or you have a bad relay or switch, but as has been said, if the solenoid contacts are shot, it won't help.
I wish I had a kickstarter.
Last edited by Uncle G.; Sep 30, 2010 at 06:17 PM.
Road Master
Joined: Aug 2010
Posts: 1,205
Likes: 18
From: SE Michigan
My solenoid contacts lasted 17 years and 160,000 miles with an occasional cleaning until this year. They're now worn too far to get reliable contact. The positive contact is eroded to a fragile thin web, and you can see signs where the center washer has welded itself to the contact and broken again. I've been messing with the prospect of rebuilding the solenoid contacts, but, given the age of the entire starter, I might be better off replacing the entire motor.
I've had the push button cover for a few years, and it helps if the battery is weak, or you have a bad relay or switch, but as has been said, if the solenoid contacts are shot, it won't help.
I wish I had a kickstarter.
I've had the push button cover for a few years, and it helps if the battery is weak, or you have a bad relay or switch, but as has been said, if the solenoid contacts are shot, it won't help.
I wish I had a kickstarter.