I'm sure this question has been ask before but....
I have a 05 Super Glide Custom. When I hit the start button all I get is a slight click out of the starter. I tested the battery it was 12.5 volts. I proceeded to remove the starter by disconnecting the wiring and removing the 2 allen bolt mounting it to the housing when I tried to remove it the starter wiggled away freely except the plunger was stuck against the fly wheel and would not easily retract. Is there something else that needs disconnected or is this potentially my problem?

 

Unless they have changed things...you will have to remove your outer primary cover and remove some "parts" from the end of the shaft. I just said "parts" to keep it simple. Once you get the long bolt out...you have to remove a few things so the starter will slide out the other side. But....wait a minute. Just a click could mean lots of things and maybe you don't have to pull it out. Check the ground connection where you removed the lower starter bolt and see if you notice any corrosion. Clean the cable end up and bolt the starter back in and try it. Next thing to check is right there behind that square-looking cover that comes off with three bolts. Take off the cover to find the plunger. Check the contacts real good here also and clean them up as well as the disk on the plunger. If you get a good loud "click" at the starter...the solenoid is pulling in, but may not be making good contact. If that "click" is elsewhere, it's likely the starter relay pulling-in and it may be defective.

Don't overlook a bad battery connection, or a bad connection where the main battery lead connects to the starter.

Yanking the starter out is not going to allow you to do all these checks unless you bench test it with a battery. Do all this first before you pull the starter.

 

went threw the check list in the order you suggested and it turned out the be the relay thx a ton for the advise.

 

Let me tell you another thing you can do that will cut starter trouble diagnostics in half....and will get you started if half the other crap ahead of it fails.

You can replace the "square-looking" cover over the end of the solenoid with the push-button type used by builders. They are relatively inexpensive and simply bolt right on in place of the stock cover. If the handlebar switch, wiring or starter relay fails....all you have to do is push this button in to engage the starter. As long as you have battery and a good starter....it WILL crank.

Now....you have to remember that anytime you push this button the starter will engage, but you still need to have the ignition switch on for it to start. Some idiot could push it while it's sitting there not knowing what it is and the bike will move and possibly turn over....as on the ground. After you pick your bike back up....you can knock his a!! on the ground for pushing the button!

It's been a life saver for a couple of my buddies that have had relays fail. Just had one on a friends bike go bad last month and I had already talked him into getting one of those covers....it came in mighty handy and you can find them on e-bay. They do not interfere with the regular handlebar starting....just a good back-up.

One more thing....usually, the brake-light and starter relay are the same type. I have swapped them to get somebody cranked and then swapped them back so his brake-lights would function until we could get to a shop and purchase a replacement relay.

You are very welcome!