I have a 1991 1200 Sportster. I bought a repair kit for the solenoid, which did not come with the ball and spring for the plunger. Bought the ball and spring thinking "quick fix" and inserted the ball into the shaft where the plunger rod goes. Now the ball is stuck and I cannot get it out, and I don't think it needs to go in. How do I remove it?
By the book. The plunger ball gets installed and removed from the inside of the starter. The hole on the plunger end under the triangle cover is smaller than the ball. The ball can be popped in from the plunger end but won't come back out.
You could drill the opening of the hole out a tad to get the ball out if need be. Then use the pictured magnet to retrieve the ball.