The other night about five miles from home, I started the engine and the starter wouldn't disengage. Rather than messing with the abbreviated tool kit under the right side cover, I rode the bike home and removed one of the battery leads to stop the starter from spinning.
Instead of trying to replace the OEM solenoid I picked up an STD SS581 automotive solenoid at O'Reilly Auto Parts for $28.75 including tax. They only had a couple solenoids in the store and both were quite large, so I bought the least expensive one.
I fabricated an aluminum plate bracket that raised and set the new solenoid closer to the battery by about 1/2 inch. I had to bend the battery cables to get them to fit the new solenoid. And then using electricians tape sealed with PVC cement or shrink tubing I covered all four terminals.
The contacts in the old solenoid had welded together. I am hoping that this larger solenoid will carry the current to the starter better than the OEM solenoid.
Instead of trying to replace the OEM solenoid I picked up an STD SS581 automotive solenoid at O'Reilly Auto Parts for $28.75 including tax. They only had a couple solenoids in the store and both were quite large, so I bought the least expensive one.
I fabricated an aluminum plate bracket that raised and set the new solenoid closer to the battery by about 1/2 inch. I had to bend the battery cables to get them to fit the new solenoid. And then using electricians tape sealed with PVC cement or shrink tubing I covered all four terminals.
The contacts in the old solenoid had welded together. I am hoping that this larger solenoid will carry the current to the starter better than the OEM solenoid.