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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #31  
Old 2 Weeks Ago
The Doctor71 The Doctor71 is offline
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Until the motor (aka the 1000cc motor) spins over great..... one is never out of the woods

In any event, since you're concluding the solenoid(s) are bad..... you might consider cleaning up the "original" solenoid. If the solenoid coils are still ok, a little cleanup may be all that's needed. You won't know until you get inside..... so your mileage may vary on this one.

This is what an OEM solenoid looks like inside..... no big deal to clean 'em up. Of course, do whatever works for you.

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  #32  
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Yes, Have used a pocket knife type file blade to remove flush insulator segment .

This does not seem to be your problem though. After market solenoids from what you are saying are the problemo.
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  #33  
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Im pretty sure you have a mechanical Issue in that the solenoid is not making contact on the big connections.

There is the posibility that the shift fork is bent or incorrectly installed and may be preventing the plunger from getting full travel.
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  #34  
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Problem solved. Ryder Rick was correct, my testing was flawed. The plunger needs to be in the solenoid for electricity to pass through the two big terminals. Thank you all.
Related question - assembly order of solenoid/plunger/boot - Does the boot go on from the right side of the housing, and then the solenoid bolts up?
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  #35  
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Default 74 sportster solenoid

Right side with gasket then finish on the left.Look at Doc's pic for reference.
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  #36  
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Yup, sungod got it.

Parts outlined in RED, left side. Everything else, right side.



The final roll pin can be a PITA to install. Be patient. I use 2 pliers..... 1 to push the cup & spring inboard, the other, needle nose, to install the roll pin. Do whatever works for you.

When done it looks like this:

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