Chopper 2004 Starter removal for dummies

[Purple Chopper]

Hi Guys, help with starter removal, I found an excellent "how to check your solenoid" on here, but can't find a detailed "how to pull the starter motor out". The problem that I have is

Pressing the starter on the handle bars, just gives a clicking sound.
Remove the chrome cover (3 screws) from the solenoid plunger, then push in by hand, and its turns over and starts.
Leaving the cover off, I can even use the handle bar starter button, but put the cover back on, and its back to just "a clicking sound" Its almost like the plunger is sticking in the chrome cover!!!!

I am now using the chopper with solenoid plunger cover removed, and the plunger is in my pocket, not the best way to operate, but I am still on the road. To start the bike I put the plunger in the housing, give it a wiggle to centralise it, then start as normal, once stated pull out the plunger, and pop it back in my pocket. (I don't want to use this starting procedure when parked outside a motorcycle shop)

HELP.....

 

[RRRUFF]

Likely cause of your starter problems are the contacts in the solieniod need cleaning. Sometimes the contacts will arc and cause pitting on the contacts and will not send enough power to the starter motor. Check the "how to's" for starters.

http://www.bigdogbiker.com/forums/how/10327-how-clean-solenoid-contacts-starter.html

 

[Purple Chopper]

Thanks RRRUFF, but the contacts all look good, and it's OK if I use the manual method. Could the solenoid be weak? I take it that it makes a magnetic field, that then pulls in the plunger. Just a thought.

 

[RRRUFF]

Could be the solieniod. You can also get a push button plunger for the solieniod. Some of the guys here may have a spare solieniod off an old starter that you could just swap out.

 

[LARS]

May just be starter relay if you still have EHC.

 

[Dakotabos]

Mine has been like that for 2 years I use the slam button. I will check mine out when winter and colder weather rolls in but the weather here in Southwest is too nice for down time

 

[stlmikie]

Check to make sure the green wire is making a good contact. I had an ongoing issue for a couple years and it turned out to be that.

 

[Five Five]

clean your solenoid and check connections