Question about 2000 Harley Davidson XL 1200 C Sportster Custom
Look at the end of your starter from the right hand side of your bike. You'll see a plate that is shaped kind of like a pentagon, five sided. It's held on by three small screws. Disconnect the battery and remove the screws and take the plate off. Under the plate, there will be a plunger and a spring. Take these out. You'll see two large copper contacts inside the solenoid. There is also a large copper washer around the plunger. When you push the start button, the starter relay closes and sends current to the solenoid. That current pulls the plunger inward and the large copper washer is supposed to make contact with the two large copper contacts on either side of the solenoid transferring high current voltage to the starter motor. Now, Look at the copper contacts and see if the large washer has burned a place in either or both of the side contacts. If so, you need to replace the contacts You can get everything you need as a kit from aftermarket sources or you can buy the parts individually from Harley.
Also look to see if the two contacts are "flat' against the coil in the back of the solenoid. If someone has tried to tighten the nuts of the starter cables, sometimes the contacts will rotate with the nut. When this happens. the large washer contacts the "twisted" contact but cannot contact the other one. They both must be "flat" against the coil.
To test the setup, reconnect the battery and reinstall the plunger. Make sure your bike is in neutral with the ignition switch off. Use a big screwdriver and push the plunger straight inwards until it stops. The engine should turn over. If not, you've got other starter problems.
Hope this helps.
Posted on Jul 22, 2010
Please try to verify that your battery is fully charged,lights and horn may be a good enough indicator especialy if it is low. The clicking sound may just be low voltage.Check the condition of both ends of the battery cables.
Posted on Aug 05, 2010
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Posted on Jan 02, 2017
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