Replaced starter gear then torqued to 5 lbs,fired up,fine? replaced primary and now wont start?
Experts, I recently replaced my starter jackshaft gear on my 2000,fatboy in an attempt to remedy my starter failure, I replaced the worn gear that showed signs of several missing teeth with a new gear,Then tested it and everything seemed fine so i replaced my primary cover,tightened everything to specs,replaced primary oil went to fire up motor and got a high pitch zing sound? I repeated process 3 more entire times and every time was the same?It starts with primary cover off only?
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Re: Replaced starter gear then torqued to 5 lbs,fired...
Well, first off....Dont try starting it anymore without the primary, it can damage the gears. The problem you describe is common with custom builds. I'll assume you purchased the correct stock jackshaft for your model and installed the lock plate and everything else correctly. You can tighten the jackshaft bolt to 7-9lbs. Your last step is putting a wrench on the assembly and pulling it out and turning 1/4 turns to make sure its not binding, as a last resort you can bevel the jackshaft bushing on the out primary so it goes in smoothly - thats what I did on mine and it works like a charm. Good luck
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Sound like starter is stuck. Try giving it a tap with a rubber mallet, while pressing start button. If this does not work, put bike in gear and push it forward a few feet, then try again to start it. If still nothing try using jumper cables on battery, then start. If no go you have a bad starter.
Your starter is connected to a jackshaft Assembly behind your primary cover. A long 1/4" bolt attaches them together. You need to remove the bolt. There is a coupler that joins the starter to the jackshaft that may fall out behind you primary, don't lose it and make sure it is put back on in the right direction when reassembeling. The torqe on the jackshaft screw is minimal (like 7 to 10foot lbs) and don't forget to use some blue locktite on it.
Pull the spark plugs out and hit the starter. This will make sure that the engine is not locked up. If the starter does not turn the engine, put the bike in first gear and have someone push you, making sure the engine is free. If the engine is OK, your starter is probably jammed and needs replaced. That wire getting hot is a dead giveaway something is locked up tight...starter or engine. If ya have a large hi-performance engine in the bike, chances are your stock starter won't do the job.
Its not a tough fix, You need what is called a starter clutch pack. NOT a new Starter. Your problem may be tools. You need two long allen wrenches. You need to remove ypur primary cover to remove the bolt in your jack shaft. You need to remove the wires to the starter. ALWAYS disconect your battery if you dont want to see sparks fly. Then its wiggle wiggle wiggle to get the starter out at times its necessary to loosen and lift oil bag. Depends on how much after market chrome you have also. good luck.
- If the starter is turning the motor , I dont understand why u replaced the relay and the ignition....but - thats water under the bridge now .... Open the primary and check the jack shaft... put a pliers on it - pull it out and turn it 1/4 turn a few times - make sure its not binding. Take a look at the bushing on the outer primary.... may need to bevel the edges a little. Make sure the battery is charged enough to give the engine a few strong turns. Let me know what you find
Its not a complcated procedure. You'll need to open your primary. You install the jackshaft into the starter after its mounted. Make sure you put plenty of ani seize into the bushing on the outer primary and watch out not to over torue the jackshaft bolt - the spec is 5 lbs.
heres a couple of links that will give you more info. One is for a spyke starter install, but all starters install the same. The other is for a belt drive install which talks some about the starter
ok bro' couple of things going on here. we'll start with the starter haha! how does it start you ask? the starter button hots up the sarter motor with the 12 volts dc which engages the starter gear wit the CLUTCH BASKET which has a ring gear in it and of course the starter is spinning and it spins the clutch basket and pulls on th primary chain if your fatpunk I mean fat boy is stock and pulls on the motor sprocket and turns the motor. If no motor power to the wheels and no starter power to the motor then something in between is broke. so I think the clang you heard was the demise of your primary chain or the clutch basket or the engine sprocket I think the primary chain is most likeley. so take it easy off the line until you hop it up proper son it ain't no hot rod til you drop some mods on it