thanks WSW; Starter solenoid replacement steps

toadstool

toadstool

Active Member
I received my starter solenoid assembly today from Wild Steed Worx, thanks guys. I am not mechanically inept although I am not familiar enough with my bike to start tearing stuff off to get to the starter. I found several links on this forum about replacing the starter but they are DEAD links and no longer working. Does anyone have a step by step guide on how to replace the solenoid and is this possible to do without removing the primary cover and starter itself? Could I remove the three screws on the end cap and just remove the solenoid from WSW's assembly and place it in my existing case?
Thanks everyone
 
KaptinAmerika

KaptinAmerika

Guru
Sorry toad but your going to have to pull the starter to do the swap.
Being a Mutt you have a bit less room than others so break out the drink and music and be the Bulldog.

Disconnect the negative on the battery and wrap it so there are no accidental shorts.
Remove the positive Cable at the top of the starter.
Remove the solenoid actuation wire on the back side of the starter, it just pulls straight out. Put dielectric greas eon it when you put it back together.
Remove the 2 starter mount bolts that are on the top 2 o'clock position and bottom 7 o'clock position going into the primary.
Note that the negative battery cable is installed with the top mount bolt.
At this point the starter will put straight out of the primary and out of the bike.
You may have to pull you pipes, pulley cover and belt to more easily remove the starter.

Now you have the starter sitting on your bench.
Disconnect the starter Motor lead going to the solenoid lug.
At the other end of the starter are four bolts that hold the nose onto the solenoid and the starter motor housing.
Remove all 4 bolts.
Now gently pull the nose portion off the solenoid and starter housing.
Pay attention to the location of the gears and bearings as you are separating it to facilitate putting it back together.
Pull the starter solenoid off the starter motor case.
Put a little grease on the starter motor case o-ring and slide the new solenoid onto the starter motor housing.
Grease the gears and bearings when you put them back together on the solenoid housing.
Using a flat head screwdriver raise the larger drive gear up a little as you slide the nose back onto the solenoid housing so it engages with the starter clutch gear. THere is a lip on the starter clutch gear that you have to clear before it will slide on.
Put red loctite on each of the four screws and put them back in the starter and tighten them down securely.

Put the starter back in reverse of removal.

This a quick and dirty to get you going.
There is actually allot more to do to really make the starter bullet proof but this is not the place to try and write that manual....LOL
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
KaptinAmerika said:
Sorry toad but your going to have to pull the starter to do the swap.
Being a Mutt you have a bit less room than others so break out the drink and music and be the Bulldog.

Disconnect the negative on the battery and wrap it so there are no accidental shorts.
Remove the positive Cable at the top of the starter.
Remove the solenoid actuation wire on the back side of the starter, it just pulls straight out. Put dielectric greas eon it when you put it back together.
Remove the 2 starter mount bolts that are on the top 2 o'clock position and bottom 7 o'clock position going into the primary.
Note that the negative battery cable is installed with the top mount bolt.
At this point the starter will put straight out of the primary and out of the bike.
You may have to pull you pipes, pulley cover and belt to more easily remove the starter.

Now you have the starter sitting on your bench.
Disconnect the starter Motor lead going to the solenoid lug.
At the other end of the starter are four bolts that hold the nose onto the solenoid and the starter motor housing.
Remove all 4 bolts.
Now gently pull the nose portion off the solenoid and starter housing.
Pay attention to the location of the gears and bearings as you are separating it to facilitate putting it back together.
Pull the starter solenoid off the starter motor case.
Put a little grease on the starter motor case o-ring and slide the new solenoid onto the starter motor housing.
Grease the gears and bearings when you put them back together on the solenoid housing.
Using a flat head screwdriver raise the larger drive gear up a little as you slide the nose back onto the solenoid housing so it engages with the starter clutch gear. THere is a lip on the starter clutch gear that you have to clear before it will slide on.
Put red loctite on each of the four screws and put them back in the starter and tighten them down securely.

Put the starter back in reverse of removal.

This a quick and dirty to get you going.
There is actually allot more to do to really make the starter bullet proof but this is not the place to try and write that manual....LOL
Click to expand...
Hey Curtis,

Are you back up and running on starter rebuilds again, or still on hold?

Sent from my 831C using Tapatalk
 
KaptinAmerika

KaptinAmerika

Guru
Unfortunately were still on hold.
My parts supplier has fallen down on me and apparently can't get back up so I am working on a new one.
 
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