Sorry if asked and answered 1000 times already, BUT, bike began not starting reliably when pressing starter button 2 weeks ago. Press button....nothing happens. Press it again, maybe again, it starts. Problem got much worse in a day of riding a week ago. Noticed can hear a single click at the starter when button is pressed. Battery checks out ok. Starter relay switch is ok too. Bike has 55,000 miles on it.

What is the problem or where should I start replacing parts? Replace solenoid? Replace entire starter?

Presuming someone is willing to give me some advice, can anyone tell me where to find instructions to make the repair? The original manual isnt adequate for a mechanically inclined guy with little engine mechanics experience.

Thanks in advance!

 

Looks like this belongs in Troubleshoot Threads/Electrical. If an administrator can move it, please do. New to forum!

 

The same thing happened to me back in 2007....The starter solenoid was the problem...You've already eliminated the easy parts and that is a sign the rest will be a breeze...You can get a replacement solenoid for around $25 and it's easy to swap out; but you'll have to remove the starter.

To remove the starter you have to remove the primary cover and then remove the starter gear from the starter shaft....There are 2 Allen head bolts that fix the starter to the inner primary cover and with a flashlight you can peer in from the R/H side of the bike just below the oil tank to see them...

It's not difficult at all...If I can do it, a chimpanzee can!!

 

If you like your fingers, always disconnect the battery when going inside the primary. The solenoid will kick the starter over when pulled, regardless of the key position.

 

Thanks guys. That's what I expected. Now the really crazy question.....don't laugh. Is there lubricating fluid behind the primary cover, or can I just pull it off?

 

If by primary cover you are referring to the Derby cover (round plate bolted to the outer primary) you can just pull it off. If you are referring to the outer primary and you have a wet clutch (you can tell because there are no holes in the primary cover to let air in (would be rather large holes)) you have to drain it first by pulling the drain plug in the outer primary. It is on the bottom rear of the outer primary.
Good Luck

If you don't have one a shop manual would help a lot.

 

If he has a 1990 FXR, then he has a wet clutch. The only dry clutch Evo powered FXRs were in early 1984.

 

Perfect. Again that's what I expected. I appreciate all the confirmation and help!

 

I ran into a similar problem with my 90 FLTC and the thread you want to read is the one with "clicky starter" in the title. What happens is that over time, the solenoid contacts become dirty and pitted, as well as worn away. Compounding this is the resistance increases that build up in the solenoid coil, wires and connectors meaning less voltage and not as strong of a pull on the solenoid plunger.

First fix I would say would be disconnect the battery, then open the solenoid on top of the starter and clean the contacts and plunger really well(be warned there might be a ball bearing that tries to come out of the solenoid housing when you pull the plunger, just catch it and stick it back in the hole). Add a little dielectric grease and put it all back together. You also want to clean all the connectors you can find associated with the starter, both small gauge and large gauge battery cables as well. Clean the connectors and add some dielectric grease. Reconnect the battery and make sure the terminals are clean and tight and you should notice a big difference.

If you still get the clicky starter, the thread I mentioned above has info about adding a piggybacked starter relay to feed the solenoid coil more voltage, allowing it to engage the starter more easily. I will go see if I can find that thread and link it for you...

 

I was wrong about the title of the thread, but here it is: https://www.hdforums.com/forum/evo-c...ghlight=clicky

This will be a good read for you with lots of useful info about your current situation, most without removing the starter! LOL!