A starter no one can fix Harley Ignition & Harley Electrics Discuss A starter no one can fix in the Harley Tech & Harley How-to forums; This is my last hope! I have a 1992 FXSTC with starter troubles. When I hit the switch I get a click but no engagement. It may click 1,2,3,4, or ...

[Easy]

This is my last hope!
I have a 1992 FXSTC with starter troubles. When I hit the switch I get a click but no engagement. It may click 1,2,3,4, or even 5 times and then start.
Sometimes it won't start, so I tap the starter (small hammer) and it starts.
Harley can't fix it, nor another outside shop, nor me. A new starter has been put in, a new relay, etc. Nothing seems to work. I look through the inspection cover and can see the pinion gear on the jack shaft jump a fraction but not engage. I've been dealing with this for 3 years and have talked to countless people. I've tried all the ideas they have come up with.
I can't afford to buy a new bike just for a bad starter. Here's hoping you have an answer, because if you can't nobody can.
Thank's in advance, Joe

[lowrider01]

have you had a look at your jackshaft bushings ?

[BIGDADDY77HD]

I'm sure you've probably done it but did you check or replace the solenoid?

[Whopper]

Hi Easy, The symptoms you describe usually indicate a wiring/battery, solenoid or ring gear problem in automotive or heavy truck applications which is what I'm familiar with. Because you replaced the starter with a new one I will assume the solenoid was replaced at the same time. You also said it will crank after making several attempts or when struck with a hammer.

Assuming you have full battery voltage available and at the starter when attempting to start, and a good solenoid, I suspect a worn or damaged ring gear or incorrect starter timing.

Because an engine will stop on a compression stroke when shut off, on a V-Twin it is the same two areas of the ring gear that get hit by the pinion when attempting to start. These areas get beat up and sometimes raise a burr which hangs the pinion up and prevents it from going into engagement, called an abuttment. There usually are some angles cut into the abutting faces of the ring gear and pinion to prevent this problem but when badly worn they don't do the job. Starters are typically designed to not energize the motor until the pinion is engaged in the ring gear or until an abuttment spring is compressed to thrust the pinion into engagement as the starter motor begins to turn.

Repeated start attempts can cause the pinion to rotate slightly so that eventually the pinion tooth aligns with a space between teeth on the ring gear and you get a start. The same can happen when you hit the starter with a hammer.

I would inspect the ring gear condition looking for sharp edges or burrs that could hang up the starter pinion.

[Easy]

Thanks for the info guys. I'll report back in acouple of weeks when I have time to work on it.

[1haugster1340]

Check the battery or try a friends battery that you know is good. A faulty battery can cause from weird things to happen. Also check for a bad ground wire. Jusy my 2 cents.

[Easy]

Haugster,

Thanks for the tip, but everything was replaced including the battery,
except the jack shaft bushings. When I get time I'm going to change them out.
Thanks again.

[evoKENevo]

Yo,"Easy"

Did you read/digest "Whoppers" post/reply here ?????