So I replaced my soenoid last week, and I developed a nasty oil leak at that area. So I bought a new boot and replaced it. I still have the same leak. It's not a small leak, I can't ride the bike far because it really leaks. I pulled the solenoid off, and the boot was not pinched. I'm at a loss.

Years ago, there used to be a large o-ring that Harley used, but they "upgraded" the seal. What am I missing? Has anybody else had this problem? It's driving me nuts because it should be a simple thing and I can't see anything incorrect about how I put the boot on, and it's not pinched....it's sitting where it should be.

 

You mean the felt giant O ring thing?

 

Correct. There used to be a giant o-ring, now they replaced it with a boot. To replace that boot, you have to remove the primary cover. The boot fits over the plunger assy, and it has a lip that takes the place of the giant o-ring.

 

I dunno. If that's where you are leaking from, either the boot is not in there properly, or doesn't fit right. If you had the giant O ring before, I'd pull that boot off and put another giant O ring back in. Any aftermarket shop should have one for you.

 

Mine is doing the same. New boot and solenoid. Oil running out when running. thinking about running a bead of black RTV around the solenoid to see if it will seal to the boot.

 

figured out what's wrong....harley gave me the WRONG solenoid....the distance from the bolt hole to the end of the solenoid is approx 1/2" on the original solenoid......but the new solenoid harley sold me the distance is approx 1/4".....which means there is a 1/4" gap that will never be filled....that's how it's leaking....I dont have the reciept but I'm bringing it back and bitching big time.....I'll throw the old one in for now....


BTW, the part number they sold me is 31489-79B


the old solenoid has a prestolite number.......SAJ-4011A....dont know the HD part equivalent

 

Thanks for posting that. I will pull mine and measure. I run a prestolite starter makes sense to have a prestolite solenoid.

 

It's interesting to note that the harley part number is correct for my bike, but the solenoid is wrong......the dealer is ordering me another solenoid, let's see what harley ships me this time.....

 

Checked my new solenoid to the old one and it is the same. Buddy told me there are two types of old style barrel noids. One tab or two tab. The boot must be exact and is a pita to get right. He said a little sealant will help hold it in place but can still move cause of the long spring. Guess I will try again tomorrow. Hope this helps.

 

Yeah i'm working on one now and don't know if the boot goes on the inside of the primary case, or does the lip remain outside the case?
Any help appreciated!
Gb