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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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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

Posted on Oct 27, 2008

  • Mel Jacobson
    Mel Jacobson Oct 28, 2008

    BTW - Harley will tell u a spinning starter that doesnt engage is cause by the jackshaft not put together right, or a bad armature or idler gear or a faullty starter clutch

    fyi

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Put new clutch now starter barely hit gear after bikes starts it a 98 custom softail thank EZ

Posted on May 07, 2009

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