About Roy Fowler Expertise Any questions about Harley-Davidson motorcycles, from flatheads to twin-cams. If I don't know, I'm not afraid to tell you!
Experience Factory Certified Harley mechanic (HD Factory Service School, Milwaukee) Worked in numerous dealerships in Florida, Mass., CT, and RI. Did his first top end job in 1969. Has owned dozens of bikes including flatheads, panheads, shovelheads, sportster, evo, and twin-cams.
Education/Credentials High school, college, and law school grad in additon to Harley Factory School and Harley update seminars.
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The text above is a follow-up to ...
-----Question-----
1998 FLH
WHEN I hit the starter button the starter spins. sometimes it cranks the engine sometimes it does'nt.
the starter spins as long as you hold the button.
but it sounds like the pinion is not staying engaged with the ring gear.I replaced the starter clutch,but it didn't seem to make much difference.
Can the jack shaft and pinion be tested?The pinion gear did not look damaged or worn.
-----Answer-----
Sounds like the solenoid,Gale. Solenoid is piggybacked to the starter and is just a big electromagnet. When the solenoid doesn't pull the plunger all the way in toward the primary, the drive gear isn't getting into the clutch ring gear to turn over the motor. The starter motor itself will spin all day long if the solenoid isn't throwing out the drive gear. You can usually see if the splines on the jackshaft are bad, but it sounds like it's the solenoid. Also, the jackshaft extension (steel tube with internal splines and a circlip inside) is meant to go on in only one direction. Did you put it on facing the right way? The internal circlip is closer to one end than the other. The end that it is closer to goes towards the starter or away from the inner primary.
follow-up:
1) I was told by local h-d dealer that the starter would not turn if solenoid was bad. incorect?
2)can the solenoid be "cleaned up" like the old ironheads/shovels where you clean the "copper washer" with sand paper?
Answer 1 Yes, if the contacts are burned or worn out the starter won't turn.
2 Yes you can clean the contacts and that big copper washer. I used to flip them over on the ones that were removable.
Did you check the spiral spline on the shaft? Did you use a NEW starter clutch? Did you put the jackshaft extension on right and the outer spring in the right place? Other than that it's one of those "I'd have to look at it".
