Solenoid Repair Kit
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Road Master
Joined: Oct 2012
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From: Beaumont, Ca
Solenoid Repair Kit
I need to install a solenoid repair kit on my 2000 Springer, and it may involve removing the starter. I understand that some bikes, from 2006 and earlier, you had to take the primary cover off. I wonder if that applies to mine, because it has a 107 CI Screaming Eagle motor and Screaming Eagle six speed transmission (replaced in 2018). Would the primary components also have been part of that renovation, as well as the starter? Once I start the removal process, and the starter is not coming off, will it become apparent that I have to remove the primary cover? Does the starter jack shaft have some kind of clip holding it inside the primary?
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Road Master
Joined: Oct 2012
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From: Beaumont, Ca
I am not looking forward to draining the oil, removing the tool kit, then removing the oil tank in order to allow access to the solenoid. It would be a nightmare trying to install the solenoid repair kit with the solenoid in place, but I may not have a choice. It is a tight fit. Have anyone done this before on a Softail Heritage (2000 Springer) without taking out the starter?
Seasoned HDF Member
Joined: May 2008
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From: South Carolina
You must remove the outer primary cover in order to remove the starter jackshaft retaining bolt.
Do yourself a favor when removing the oil tank, remove the rear wheel and the plastic fender extension.
This will give you access to the rear of the oil tank and keep you from inventing new curse words...
While the oil tank is out, inspect all your electrical stuff in that area while it is easy to get at, wires chafing, missing tie wraps, etc.
Also throw a new set of battery cables on the bike.
Do yourself a favor when removing the oil tank, remove the rear wheel and the plastic fender extension.
This will give you access to the rear of the oil tank and keep you from inventing new curse words...
While the oil tank is out, inspect all your electrical stuff in that area while it is easy to get at, wires chafing, missing tie wraps, etc.
Also throw a new set of battery cables on the bike.
Last edited by Dan89FLSTC; Jul 28, 2020 at 05:47 PM.
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From: Cleveland Zoo
I am not looking forward to draining the oil, removing the tool kit, then removing the oil tank in order to allow access to the solenoid. It would be a nightmare trying to install the solenoid repair kit with the solenoid in place, but I may not have a choice. It is a tight fit. Have anyone done this before on a Softail Heritage (2000 Springer) without taking out the starter?
Seasoned HDF Member
Joined: May 2008
Posts: 21,176
Likes: 12,753
From: South Carolina
Thread Starter
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Road Master
Joined: Oct 2012
Posts: 777
Likes: 45
From: Beaumont, Ca
Here is one crazy thought I just had. I want to disconnect the spark plug wires and remove the spark plugs (high compression motor with compression release valves) while I crank the motor and listen to and see what the actual contacts and the plunger in the solenoid are doing. I believe I hear a loud electrical type arcing noise when I crank the motor (about half a second). Those of you who have done some electrical welding would know the noise I am talking about. I will have my fingers away from the solenoid just in case. What is the purpose you ask? Just to confirm my suspicions, and possibly replace the plunger. In the past, I have only replaced the plunger when I found it too tedious to remove everything to get to the solenoid and the contacts were still good. No, this is not the right way to do it, but "that's how I roll."
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Seasoned HDF Member
Joined: May 2008
Posts: 21,176
Likes: 12,753
From: South Carolina
Your troubleshooting ideas are out in left field.
It`s a simple starter system, no science project needed to determine what is wrong.
Let`s fall back a bit...
What led you to believe the starter solenoid needed to be rebuilt?
What exactly is the issue with your bike?
It`s a simple starter system, no science project needed to determine what is wrong.
Let`s fall back a bit...
What led you to believe the starter solenoid needed to be rebuilt?
What exactly is the issue with your bike?
Last edited by Dan89FLSTC; Aug 1, 2020 at 08:31 AM.
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Thread Starter
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Road Master
Joined: Oct 2012
Posts: 777
Likes: 45
From: Beaumont, Ca
Thanks for the compliment. Great ideas come from thinking out the box. As I said, I get a loud arcing sound coming from the solenoid. I suspect this is the spark jumping across the contacts perhaps because the plunger is not seated correctly. If it will help me answer that, what is wrong with it?
Seasoned HDF Member
Joined: May 2008
Posts: 21,176
Likes: 12,753
From: South Carolina
How old is the battery?
A weak battery can cause the solenoid to chatter and arc.
Poor battery connections can cause the same issue, also a loose connection at a battery terminal can cause a arc, enough to melt the battery post.
Fully charge the battery and load test the battery, clean all battery cable terminals, clean negative cable ground point.
Remove the solenoid end cover and inspect the contacts and plunger.
A weak battery can cause the solenoid to chatter and arc.
Poor battery connections can cause the same issue, also a loose connection at a battery terminal can cause a arc, enough to melt the battery post.
Fully charge the battery and load test the battery, clean all battery cable terminals, clean negative cable ground point.
Remove the solenoid end cover and inspect the contacts and plunger.
Last edited by Dan89FLSTC; Aug 1, 2020 at 10:18 AM.
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