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  #11  
Old 18th April 2009
Wooley Wooley is offline
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that plunger is close to the exhaust, maybe to prevent burns you could attach a choke lever from a string trimmer or chain saw to keep your fingers outta the exhaust. This was a cool write up especially being that my strter button went bad and I've been looking for a way to do away with the handle bar button anyway. So I guess what I want to know is: if I went this route, can I just unhook my handle bar wires from headlight bucket and remove altogether and use your idea for the sole start button. I kill the engine with the key switch anyway.
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  #12  
Old 18th April 2009
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DogBunny DogBunny is offline
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Sportster/Buell Model: XLH883-1200 Ol Black Mare
Sportster/Buell Year: 1990
Sportster/Buell Model #2: Yam. XS650 "Angry Hornet"
Sportster/Buell Year #2: 1979
Other Motorcycle Model: Yam. XS650 "Bug Killer"
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Quote:
Originally Posted by Wooley View Post
that plunger is close to the exhaust, maybe to prevent burns you could attach a choke lever from a string trimmer or chain saw to keep your fingers outta the exhaust. This was a cool write up especially being that my strter button went bad and I've been looking for a way to do away with the handle bar button anyway. So I guess what I want to know is: if I went this route, can I just unhook my handle bar wires from headlight bucket and remove altogether and use your idea for the sole start button. I kill the engine with the key switch anyway.
Yes, you will be able to unhook your wires at the headlight and remove the start button.

I kept my handlebar start button. My solenoid push-switch is just for emergencies.

If you are going to ditch your handlebar switch, I suggest you buy a manufactured aftermarket solenoid push-button. My design is a little flimsy for every day use.
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  #13  
Old 18th April 2009
Wooley Wooley is offline
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Thanks DogBunny,
It gives me another alternative and the emergency backup is a great idea.
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  #14  
Old 10th January 2010
fourteen fourteen is offline
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Quote:
Originally Posted by DogBunny View Post
Update: There is a Sportster solenoid repair kit! It contains a new plunger, spring and contact assemblies. (no gasket)

The Part Number is DS-196230
VN-P# 550000
SOLENOID REPAIR 91-04 B/T
$30
FYI, Harley also carries solenoid rebuild kits:

31604-91A STARTER SOLENOID REBUILD KITS for 1.2 kW starters
31604-06 STARTER SOLENOID REBUILD KITS for 1.4 kW Hi-Output starters
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  #15  
Old 12th December 2012
mountnmonty mountnmonty is offline
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Default Photos are not with the text now

Do you still have the photos to this write up? I have a 1985 sporty and the starter may be toast. I know if I was back on the ship we would float test it for sure.
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  #16  
Old 12th December 2012
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DogBunny DogBunny is offline
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Not in order, here are the pics.






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  #17  
Old 2nd December 2014
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madnss madnss is offline
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Whats holding the new push button rod on the inside of the housing?
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  #18  
Old 8th August 2015
Andrew_Deaton Andrew_Deaton is offline
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Sorry to Bump an old post but its not showing pictures. Just wondering if someone had any
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Old 25th August 2016
HollywoodHog HollywoodHog is offline
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Thanx for the detailed fix and pix for this common problem. l have had the solenoid guts out several times and will now perform a thorough cleaning. lf this fails l'm on my way to the hardware store to purchase a few items and turn the useless hulk in my garage into a functioning motorcycle.
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  #20  
Old 29th August 2016
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DogBunny DogBunny is offline
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Sportster/Buell Model: XLH883-1200 Ol Black Mare
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Glad to see that this old thread is still helping people. I finally fixed the pictures, they now all show up correctly in the very first post of the thread. It only took me 4 years to fix those pictures...
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