Tools and Materials Needed
- Safety glasses
- Gloves
- Socket set
- Wrench set
- Phillips head screwdriver
- Flat head screwdriver
- Pliers
- New starter solenoid
- Replacement starter motor
Step 1: Prepare the Motorcycle
- Disconnect the battery terminals to ensure safety and avoid any electrical accidents.
- Remove the left side cover to expose the starter.
Step 2: Remove the Starter Motor
- Locate the starter motor, which is usually attached to the engine's left side.
- Disconnect the electrical wires connected to the starter motor. Note their positions for proper reinstallation.
- Use the appropriate wrench to loosen and remove the bolts holding the starter motor in place.
- Gently lift and remove the starter motor from its position.
Step 3: Inspect the Starter Motor
- Visually inspect the starter motor for any signs of damage, such as cracks or burnt wires.
- Check if the starter clutch is engaged. If not, it might be the cause of the clicking sound.
Step 4: Replace the Starter Solenoid
- The clicking sound could be due to a faulty starter solenoid.
- Locate the starter solenoid, which is usually mounted on the starter motor.
- Disconnect the electrical wires connected to the solenoid.
- Remove the mounting screws and take out the old solenoid.
- Install the new solenoid and reattach the mounting screws.
- Reconnect the electrical wires as they were before.
Step 5: Test the Starter Motor
- Reinstall the starter motor back into its position and reconnect the electrical wires.
- Reconnect the battery terminals.
- Try starting the motorcycle. If it starts without any clicking sounds, the repair was successful.
Step 6: Reattach the Left Side Cover
- Reinstall the left side cover and secure it with the appropriate screws.
By following these steps, you can remove and repair a 1999 Harley Sportster starter that only makes clicking sounds. If the issue persists after replacing the starter solenoid or starter motor, it's recommended to consult with a professional mechanic.
