Motorcycle Repair: 92 XL 1200 Solenoid, clutch basket, electronic experience


Question
QUESTION: The solenoid recently started to not respond to the starter switch. I do have electrical/electronic experience and did determine that the starting circuit is sending 12 volts (green wire) to the solenoid which operates every now and then but more bad attempts than good. If I continue to press the start button, sometimes the solenoid kicks and the bike, which otherwise runs well immediately starts. I have a brand new battery. I have the ability to rebuild the solenoid but I DO NOT KNOW what I have to do to remove it. I read somewhere that I'll need to remove the primary cover to get it off. Please advise me as to the what exactly I need to do to get the solenoid off. I have wrenching experience and the gumption but am ignorant as to the steps required. I'd like to do it, obviously, the easiest way. I look forward to your advice and thank you SO VERY much in advance. Funds are limited so I'm trying to do this myself

ANSWER: the solenoid is part of the starter which will need to be removed. In order to remove the starter the primary cover has to be removed as well as the motor sprocket and clutch basket. to remove the clutch basket you will need a special tool to remove it.
SInce there are many steps i am going to advise you to get a service manual. It will give you all the steps and pics you need to do the work
Good luck and happy riding
Mike

---------- FOLLOW-UP ----------

QUESTION: i found the Harley solenoid rebuild kit number 31603-91. got any ideas if there is a aftermarket company offering an equivalent item for less than the 80 bucks the dealer wants. and if I was to pull the rear cover of the solenoid, could would this let me inspect the plunger and still be able to re-assemble?

Answer
What you need to do is look online at different companies catalogs. Try V-Twin manufacturing. They should have one. you can pull the plunger and reassemble without a problem
One other thing, I didnt notice that you said you have a sportster. In order to remove the starter all you have to do is unbolt it and remove the wires. You dont need to remove the cover and clutch
Good luck and happy riding
Mike