Mine did the same solenoid "stick" the other night, but I'm not sure if it's the solenoid that's sticking in the "engaged" position or the starter jackshaft that's sticking. If it's the latter, a new starter won't fix it. Replacing the starter jackshaft will require removal of the clutch and primary chain in addition to removing the primary cover and oil tank.

Since cleaning the solenoid contacts, I haven't had the starter miss a beat, but I know it's a matter of time before it happens again. It's probably time to spend some money. With 160,000 miles on the bike, I figure it's not worth trying to rebuild the starter solenoid. By this time, the motor brushes, commutator, starter clutch, etc, are probably getting pretty "long in the tooth". Since the labor is the same, I'll probably just throw in a new starter.

Let me know what you find out, though

 

OK, I went down again this morning I pulled the solenoid apart. Both of the brass washers were beat to crap, black and pitted as were both top and bottom contacts. I sanded them down, cleaned the tube out and hosed down the plunger with brake clean. I then re-lubed the plunger and put it all back together. It worked flawless on my 300 mile trip today to the Blue Ridge Parkway. So at least I know the problem is the solenoid. So before I order a new starter I'm gonna get that solenoid rebuild kit since YOU GUYS convinced me this fix is just temporary. So for the cost of a twenty dollar rebuild, I should be back in action for another 20K.......maybe?

 

I've said before, just because connections are tight, does not necessarily mean there's a good electrical connection. Take connections apart and wire brush, apply dielectric, then go from there. Most starter prob , if you do a search, are related to bad oconnections, depending on where you live. The connections may be tight, but rusted tight.