Nice. Thanks for that update.

 

Thanks for including steps 2, 3, and 4 of that repair sequence. Chances are I would have included them without the reminder, but this way I'll be sure to.

 

Always glad to make sure I include a thorough description and step by step instructions.

 

BTW - giving credit where it's due.
Max and TJ at Harley-Davidson of Waco (Texas) were the service guys that worked with me; spent nearly half an hour checking codes, re-wiring the battery leads and generally doing the once over and shallow dive to resolve my issue. They also gave me the tip to check/sand the copper plunger washer in the solonoid.
They could have easily just written it up and told me to wait and then try to sell me a whole starter but they sent me on my way with a good idea of where the issue was and did'nt ask for a thing.
So on top of the phone call and letter I'm sending the dealership owner AND them, I'm spreading the word of a couple good guys and a friendly helpful dealership.

 

While they were doing the preliminary once over, the relays are tucked in behind the battery. All you can see are the little plastic tabs that are attached to the body. You can use a philips screw driver to pry them up to get to the bottom and the wiring harness.

 

I'm gonna bet it will happen again...

I say that, because the 80 grit paper left a rough finish on the copper washer. It will arc, just like before, and burn the tips off of any rough edges and create the same scenario all over again. It is a good 'road fix', but should be replaced at soonest opportunity.

We used to sand the same parts on Ford starter solenoids after taking them apart. Back when points and condensers were used in ignition systems, we sanded with light weight sand paper or the smooth side of our OL's finger nail emery board. Then we would finish cleaning points with a dollar bill. The paper used in dollar bills was just rough enough to cut down the rough finish, and leave a smooth surface.

 

Nice you have it fixed, and great to hear of good service.....on my list to stop if ever i get down that way....T-Shirt and a stop in the service department to tell them about this post...makes them happy and keeps good service flowing...

 

You might want to do what I did. Replace the end cap of the solenoid with the push button type. No matter what fails you can always turn on the ignition in neutral and push the button. As long as you have enough battery that sucka is gonna spin.

 

I second that. Cheap insurance. Mine cost $22.00 at Dennis Kirk.

 

Yeah - I was thinking about that, but I dont know where to come up with a replacement plunger or if it can be broken down to replace the copper washer on its own. And even if so, where to find the washer? Can you actually find inner solonoid or starter parts? I know you could find brushes for cars, etc. and internal brush olders, bearings, brushes, bushings - but I've not seen those pieces available for HD starters - only whole units. Not even individual solonoids.

Answered my own question..DUH!...http://www.jpcycles.com/product/223-354