Question about 2004 Harley Davidson XL 1200 R Sporster Roadster

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STARTER WILL NOT ENGASGE FLYWHEEL - 2004 Harley Davidson XL 1200 R Sporster Roadster

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Hi Robert, it sounds the like starter drive/clutch has gone south, it has components inside, that when spinning, centrifugal forces cause them to grab or lock into permanently fixed counterparts. The gear only spins one way and locks the other way. If you have one that spins both ways it has failed and needs to be replaced. Please visit the web site below for more help and good luck.
Harley Davidson Manuals Mark Workshop

Posted on May 26, 2015

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Posted on Jan 02, 2017

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2000 GMC Yukon 1500xl 4wd. I replaced the starter relay and now the starter and flywheel are out of sync. The switch panel on dash is back on. How do I get them reset into sync?


the starter and flywheel cannot "unsync" unless you removed the starter and reinstalled it incorrectly! .. the starter pinion is moved "up or forward" on the starter shaft and engages the flywheel when the starter is "engaged".. the flywheel never moves from its factory installed position (unless something catastrophic happened).. the starter pinion always engages unless there is something wrong with the starter

Sep 17, 2017 | GMC Cars & Trucks

3 Answers

My starter is engaging but it is not hitting the flywheel to let it turn the engine over could that be from a bad flywheel or not haveing the shims in the starter


Yes and yes, but if you are lucky it could be a bad starter bendix. Remove starter to examine and check flywheel teeth as well.

Jun 20, 2016 | Cars & Trucks

1 Answer

Starter winding like a vacuum but won't turn over the engine


If your starter is spinning but no engaging the flywheel, then you have 2 possibilities going on here, the # 1 and most likely cause is the bendix on the starter is not kicking out to engage the flywheel so you'll need a new starter... pretty cheap fix.

# 2 is that for some reason the teeth on the flywheel have been chewed away and now the starter gear can't crab the flywheel, this would only be a secondary answer if for some reason your starter had been grinding while trying to engage. Just an FYI, this is very rare but has happened, considering that your engine flywheel stops at the same spot every time you turn your engine off, so the starter is constatly grabbing the same flywheel teeth all its life. For this fix, you'll have to have the transmission removed and have a new flywheel installed on your engine.

Jul 13, 2015 | Cars & Trucks

1 Answer

1965 mustang starter fires but won't engage flywheel. it is a brand new starter


Doesn't matter. The forks inside the starter may be missing or broke off or bad spring in starter that pushes the gear out. Try new started. Starter may have to be shimmed to make contact with flywheel. Starter may be kicking out but not engaging flywheel.

Jan 17, 2013 | 1965 Ford Mustang

2 Answers

Starter makes a screeching noise sometimes just after the motor starts


Replace the starter before it ruins the flywheel. You have a worn out drive that applies to the flywheel. Flywheels are very very hard to change, in fact you can change 10 or 15 starters in the same time changing one flywheel

Jul 24, 2011 | 1997 Buick Century

3 Answers

I have a 1996 astro van...when i go to start and turn ignition it makes this real bad grinding sound? could it be the flywheel or the starter ?


It could be either the flywheel or the starter.
If it's grinding, don't try it again until you've removed and examined the starter and flywheel. If the starter solenoid isn't fully engaging the bendix, it will cause the gear to grind; replace or rebuild the starter if that's the case.
But you should examine the flywheel to see if it is seriously damaged from the problems you've had. Put a mark on the flywheel using a magic marker, then examine the flywheel as you slowly turn the engine by hand. (make certain that the ignition is off when you do that, you don't want anything bad to happen to your hand.) The mark on the flywheel will indicate when you've been able to examine the all of the teeth on the starter ring.

Mar 19, 2011 | 1996 Chevrolet Astro

1 Answer

The starter in my 95 Isuzu is going how do i replace it


I have pasted the procedure from autozone.com below, but I also recommend you read my starter post at http://www.fixya.com/cars/r5973094-starter_replace and let me know if you have questions.

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  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle on jackstands.
  3. Label and disconnect the battery and starter control wires from the starter.
  4. If equipped, remove the starter bracket and/or heat shield.
  5. Remove the starter-to-engine mounting bolts.
  6. Lower the starter from the engine. If any shims are present, keep them for reinstallation purposes.

To install:
  1. Install the starter and shims, if equipped, to the engine. Tighten the mounting bolts to 30-34 ft. lbs. (39-44 Nm).
  2. Install the starter bracket and/or heat shield, if equipped.
  3. Reconnect the electrical connectors to the starter.
  4. Lower the vehicle.
  5. Connect the negative battery cable.
  6. Start the vehicle to make sure the starter functions correctly.


SHIMMING


Starter noise during cranking and after the engine fires is often a result of too much or tool little distance between the starter pinion gear and the flywheel. A high pitched whine during cranking (before the engine fires) can be caused by the pinion and flywheel being too far apart. Likewise, a whine after the engine starts (as the key is released) is often a result of the pinion-flywheel relationship being too close. In both cases flywheel damage can occur. Shims are available in various sizes to properly adjust the starter on its mount. In order to check and adjust the shims, you will also need a flywheel turning tool, available at most auto parts stores.
If your vehicle's starter emits the type of noise previously described, follow the shimming procedure below:

  1. Disconnect the negative battery cable.
  2. Raise and support the vehicle safely using jackstands.
  3. Remove the torque converter/flywheel cover from the bottom of the bell housing.
  4. Using the flywheel turning tool, turn the flywheel and examine the flywheel teeth. If damage is evident, the flywheel should be replaced.

Most starters are equipped with an access hole in which a small screwdriver or prybar may be inserted to push the starter pinion outward into contact with the flywheel.
  1. Move the starter pinion and clutch assembly so the pinion and flywheel teeth mesh. If necessary, rotate the flywheel so that a pinion tooth is directly in the center of the two flywheel teeth and on the centerline of the two gears, as shown in the accompanying illustration.

Normal pinion-to-flywheel clearance is about 0.01-0.06 in. (0.5-1.5mm).
  1. Check the pinion-to-flywheel clearance by using a 0.020 in. (0.5mm) wire gauge (a spark plug wire gauge may work here, or you can make your own). Make sure you center the pinion tooth between the flywheel teeth and the gauge-NOT in the corners, as you may get a false reading. If the clearance is under this minimum, shim the starter away from the flywheel by adding 0.04 in. (1mm) shims one at a time to the starter mount. Check clearance after adding each shim, but do not use more than 2 shims.
  2. If the clearance is over 0.060 in. (1.5mm), shim the starter towards the flywheel. Broken or severely mangled flywheel teeth are also a good indicator that the clearance here is too great. Shimming the starter towards the flywheel is done by adding shims to the outboard starter mounting pad only. Check the clearance after each shim is added. Add 0.013 in. (0.33mm) shims at this location, one at a time, but do NOT add a total of more than 4 shims.

Oct 28, 2010 | 1995 Isuzu Trooper

1 Answer

How to take a starter off of an 85 chevy caprice


Starter REMOVAL & INSTALLATION Fig. 1: If necessary disconnect the exhaust pipe(s) from the manifold(s) for access to the starter assembly 85313018.jpg Fig. 2: Once disconnected, the pipes should be suspended out of the way using wire or an old coat hanger 85313019.jpg Fig. 3: Although usually not necessary, the torque converter cover may be removed for additional access 85313020.jpg Fig. 4: Once the bolts are removed, the cover may be lowered from the transmission 85313021.jpg Fig. 5: The starter solenoid wiring should be tagged and disconnected 85313022.jpg Fig. 6: Various sized deep sockets will make disconnecting the wiring much easier 85313023.jpg Fig. 7: Loosen the start mounting bolts 85313024.jpg Fig. 8: Support the start and withdraw the bolts 85313025.jpg Fig. 9: Carefully tilt and lower the starter assembly from the vehicle 85313026.jpg Fig. 1: Check the gap between the starter pinion and flywheel 85313027.gif Fig. 2: Starter motor mounting — V6 (left) engine and diesel (right) engine 85313028.gif
Fig. 3: Starter motor mounting — inline six cylinder (top) and V8 engine with solenoid heat shield 85313029.gif
Starter noise during cranking and after the engine fires is often a result of too much or tool little distance between the starter pinion gear and the flywheel. A high pitched whine during cranking (before the engine fires) can be caused by the pinion and flywheel being too far apart. Likewise, a whine after the engine starts (as the key is released) is often a result of the pinion-flywheel relationship being too close. In both cases flywheel damage can occur. Shims are available in 0.015 in. sizes to properly adjust the starter on its mount. In order to check and adjust the shims, you will also need a flywheel turning tool, available at most auto parts stores or from any auto tool store or salesperson. If your car's starter emits the above noises, follow the shimming procedure below:
  1. Disconnect the negative battery cable.
  2. Raise and support the vehicle safely using jackstands.
  3. Remove the torque converter cover on the bottom of the bell housing.
  4. Using the flywheel turning tool, turn the flywheel and examine the flywheel teeth. If damage is evident, the flywheel should be replaced.
  5. Insert a screwdriver into the small hole in the bottom of the starter, then move the starter pinion and clutch assembly so the pinion and flywheel teeth mesh. If necessary, rotate the flywheel so that a pinion tooth is directly in the center of the two flywheel teeth and on the centerline of the two gears, as shown in the accompanying illustration.
  6. Check the pinion-to-flywheel clearance by using a 0.020 in. wire gauge (a spark plug wire gauge may work here, or you can make your own). Make sure you center the pinion tooth between the flywheel teeth and the gauge — NOT in the corners, as you may get a false reading. If the clearance is under this minimum, shim the starter away from the flywheel by adding shim(s) one at a time to the starter mount. Check clearance after adding each shim.
  7. If the clearance is a good deal over 0.020 in. (in the vicinity of a 0.050 in. plug), shim the starter towards the flywheel. Broken or severely mangled flywheel teeth are also a good indicator that the clearance here is too great. Shimming the starter towards the flywheel is done by adding shims to the outboard starter mounting pad only. Check the clearance after each shim is added. A shim of 0.015 in. at this location will decrease the clearance about 0.010 in. Battery and Starter Specifications Chart
    Battery and Starter Specifications Chart (Cont...)
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Sep 01, 2010 | 1985 Chevrolet Caprice

3 Answers

When starter turns engine does not


Remove the starter shields and check the starter drive. Does it fly out when the starter is engaged? Check the flywheel for ring gear damage from the starter. Check the flywheel for breakage at the crankshaft, try to turn the engine using the flywheel with a screw driver.

Sep 09, 2009 | 1998 Chevrolet Malibu

2 Answers

Cost to replace starter & flywheel on a 2003


for the starter and flywheel 1400 sounds right they would have to take the tranny out to get to the fly wheel but why do they need to replace the fly wheel did your old starter do a lot of grinding its not to often you have to replace a flywheel unless the starter wrecked it somehow again not to often starters are ment to break before it wrecks the flywheel the flywheel made of harder metel i would get a second opinion on replacing the flywheel

Aug 27, 2009 | 2003 Ford Taurus

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