Question about 2002 Harley Davidson FLHTCUI Electra Glide Ultra Classic

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I've replaced my starter twice what happens is the gear at the end of the shaft, doesn't engage all the way and will start chipping the teeth. any advise or help would be great.

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Usually, the contacts in the solenoid of the starter ensure that the starter gear is fully engaged before it starts the starter motor. But, if the contacts are not positioned correctly, the starter motor will start up before the gear on the jackshaft is fully engaged.

Remove the end of the solenoid. That's the five sided plate held on with three small bolts. You'll see two large copper contacts after you pull the plunger and spring out. Make sure these contacts are straight and as far back as they will go. Make sure they aren't twisted due to tightening of the bolts that hold them into the solenoid and that they are not bent outward at the bottom. You want the plunger to be as far into the solenoid as possible before it makes contact with these two contacts. Check the large copper washer on the plunger as well.

Good Luck
Steve

Posted on Sep 14, 2010

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