Question about 2004 Harley Davidson FLHTCUI Electra Glide Ultra Classic

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Starter shaft keeps breaking.. gone thru two , what else coul;d cause this shaft to break? thanks

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I assume you're talking about the starter jackshaft. I'd suspect that there is a misalignment between the starter and the bushing in the outer primary. I'm reluctant to say this but you may have to pull the dowel pins out of the inner primary that are supposed to align the outer primary up with the inner. I've heard of them being improperly placed causing this misalignment.

Now, if for some reason you have the inner primary off, you may can bolt the inner and outer together without the starter on the inner and take it to a machine shop to have the alignment checked. I've never done this but I had one checked once. The machinist cuts a bar or tube that fits the jackshaft support bearing in the outer primary. It's long enough to protude up through the starter hole in the inner primary. With this, he checked the alignment of the primary covers. You may can just use the jack shaft to check it with, I have never tried that. I've done one like this but I can't say that I fixed it because the guy has not come back with another broken jackshaft. I think he would if he broke another one.

Good luck
Steve

Posted on Jul 21, 2010

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