Shovelhead starter solenoid sealing

I rebuilt the starter solenoid on my 1977 FLH Harley Davidson shovelhead, then realized the plunger boot was shot so here's a video on the reassembly. This bike is running a sealed primary with no auto oiler, so it pulls no vacuum and was leaking like a son of a gun. It's been a few weeks and my tweaks on the original seal design worked great. It hasn't leaked a drop. Hope it helps someone!

[@stevepotter6770]

If you use zip ties/ cable ties it makes it easier to compress the spring, plus you only have to snip them and pull them out afterwards.

[@arthurleino]

I use to take my Shovelhead to a old school mechanic. He used Seal on primary, rocker cover gaskets. I think he taught me well. Great video!

[@licarico]

thanks Art! appreciate that.

[@williammusser7043]

Thanks for the close-up on the solenoid assembly; factory manual doesn't give a very good explanation of the orientation of the spring, roll-pin, and end keeper.

[@darrengabbe653]

I had the same problem. Should have taken a pic before pulling it apart. Was throwing starter gear but not retracting. I had the pin on the wrong side.

[@gildriver8717]

hello i'm working on a 73 shovel FL SIDE CAR POLICE SPECIAL, first time seeing your video been looking for this exact fix THANKS, I'm in the process of going through the bike this winter cleaning clutches and other small leaks. However your video was much needed and the details helped out great.

[@user-oc3dw9tf6v]

I wish I would have seen this video before I paid someone to replace my selonoid! Mine leaks so bad down the primary! Great video!!!

[@scottkettler6946]

RL Burnside background - awesome

[@licarico]

can't beat it!

[@everydaylife1885]

One of the better videos

[@licarico]

thanks, appreciate that

[@IrvingtonArms]

Mine had an O ring rather than a washer but this was super helpful. Im about to redo my sealed primary that pukes oil from my rotted boot.

[@stevemiller7654]

Why not vent the primary like the 5-speed Evos do, through the mainshaft? Just remove any seals in the clutch hub nut, and the internal pressure will bleed off through the transmission, and out its vent screw....

[@dennman8832]

2 year old post but in your primary the chain adjuster shoe is on backwards.The narrow ramp goes to the front.

[@licarico]

Haha nice catch! She's all right now.

[@darrenrabinowitz4304]

I like to always use hylomar on Harley s and I do use yamabond on the cases

[@licarico]

as long as its good quality stuff and you do the prep work well, it'll hold up!

[@freedomthief8499]

Great yo watch,...Great music,..
.am on it,...!
Maximum RESPECT 🔥
From Athens Greece 🇬🇷

[@tomconte1765]

You didn't disconnect the battery did you?

[@royhawkinshawkins2801]

Nice info on the video. Is there a "trick" to taking the spring and end cap off the plunger? Should I keep the solenoid on to compress the spring in the primary?

[@licarico]

Yeah it needs to come off before you can remove the solenoid. I just used some needle nose to hang onto the spring while pulling it apart. A telescoping magnet is handy for keeping stuff from falling

[@dingfarquar6603]

OK,... now, replace that rubber boot on the shaft that goes to the solenoid..! What is the secret?

[@licarico]

You mean the boot I replaced? Ya gotta pull that pin out first then you can slide the new boot on.