Starter jackshaft bolt seems to be to short to bolt back up to starter why.

The jackshaft must be installed back onto the starter shaft prior to installing the jackshaft with the shallow side of the coupling going/facing towards the jackshaft and also facingthe jackshaft splines. Remember to reinstall the coupling retaining ring if it was removed. ALSO, be sure to install the coupling on the starter output shaft with the counter bore facing the jackshaft. THEN put the spring inside the coupling and install the pinion gear on the shaft put the lockplate and the thrust washer on the bolt and put the bolt in place in the jackshaft. If you removed the retaining ring put it back on shaft and then slide the jackshaft assembly back into position in the inner primary. In order to hold the lockplate and thrust washer in place be certain that the lockplate tab is properly in the keyway. THEN, having aligned the lockplate tab and thrust washer properly in the slot with the jackshaft keyway screw the jackshaft bolt into the starter shaft and while holding the pinion gear in position tighten the bolt to 84-108 in-lbs (9.5-12.2 Nm) and bend the locking tab against bolt head.

The jackshaft must be installed back onto the starter shaft prior to installing the jackshaft with the shallow side of the coupling going/facing towards the jackshaft and also facingthe jackshaft splines. Remember to reinstall the coupling retaining ring if it was removed. ALSO, be sure to install the coupling on the starter output shaft with the counter bore facing the jackshaft. THEN put the spring inside the coupling and install the pinion gear on the shaft put the lockplate and the thrust washer on the bolt and put the bolt in place in the jackshaft. If you removed the retaining ring put it back on shaft and then slide the jackshaft assembly back into position in the inner primary. In order to hold the lockplate and thrust washer in place be certain that the lockplate tab is properly in the keyway. THEN, having aligned the lockplate tab and thrust washer properly in the slot with the jackshaft keyway screw the jackshaft bolt into the starter shaft and while holding the pinion gear in position tighten the bolt to 84-108 in-lbs (9.5-12.2 Nm) and bend the locking tab against bolt head.

Sorry 1984 is back beyond my expertise and/or knowledge but later model years jackshaft might be somewhat similar:

Disconnect the negative battery cable. THEN remove the primary cover. (If you are only going to service the items from the bolt through to the spring it is not necessary to remove clutch but if it is desired to replace the coupling and/or the retaining ring it will also require starter removal. So, bearing that in mind, if necessary, next remove the clutch assembly. THEN while holding the pinion gear in place remove the jackshaft bolt, the lockplate and the thrust washer and remove the jackshaft from the inner primary as an assembly. THEN remove the pinion gear from the jackshaft and then remove the coupling and the spring. The spring and the retaining ring are inside the coupling. Replace the retaining ring if deemed necessary. ALSO if the coupling is forced through the primary case oil seal you will necessarily have to replace the seal as it will be ruined. THEN remove the coupling from the starter shaft and if needed replace the retaining ring. The jackshaft must be installed back onto the starter shaft prior to installing the jackshaft with the shallow side of the coupling going/facing towards the jackshaft and also facingthe jackshaft splines. Remember to reinstall the coupling retaining ring if it was removed. ALSO, be sure to install the coupling on the starter output shaft with the counter bore facing the jackshaft. THEN put the spring inside the coupling and install the pinion gear on the shaft put the lockplate and the thrust washer on the bolt and put the bolt in place in the jackshaft. If you removed the retaining ring put it back on shaft and then slide the jackshaft assembly back into position in the inner primary. In order to hold the lockplate and thrust washer in place be certain that the lockplate tab is properly in the keyway. THEN, having aligned the lockplate tab and thrust washer properly in the slot with the jackshaft keyway screw the jackshaft bolt into the starter shaft and while holding the pinion gear in position tighten the bolt to 84-108 in-lbs (9.5-12.2 Nm) and bend the locking tab against bolt head. THEN reinstall the clutch assembly etc. and the primary case etc using new gaskets as required etc., refill the primary with oil, reconnect the negative battery cable and check to be sure you have not forgotten anything.
CAUTION

To take the starter off your bike, first, you need to disconnect the cables from the battery and remove the battery. Then, drain the primary case and remove the outer primary cover. Remove the seat from the bike. Take the small bolt out that holds the starter jackshaft in and remove the jackshaft. On the early models, there is a small o-ring that you need to replace, you'll see it when the take the bolt out of the jackshaft if your bike has one. Once you have this off, go to the other side of the bike and remove part or all of the exhaust system to enable you to reach the starter. On a Softail bike, you'll have to remove the bolts and supporting rubber grommets from the oil tank. Do not take any oil lines loose. All you need to do is raise the tank just a bit to get to the rear bolt that holds the starter on. Disconnect the positive battery cable and the single small wire from the starter. Remove the two large socket head bolts that holds the starter on. When you take the starter off, there is a coupling that connects the jackshaft to the starter. Mark the direction that it goes in or the counter bored end goes towards the jackshaft. To put the starter back on, reverse these procedures.

Good Luck

steve

I assume that you want information on how to replace the starter on a Fat Boy. First, disconnect and remove the battery. Then drain the oil from the primary and remove the outer primary cover. Take the small bolt out of the starter jackshaft and remove the jackshaft. Then go to the right side of the bike and remove part or all of the exhaust system as necessary to gain access to the starter. Take the bolts and mounting hardware loose from the oil tank so that you can lift the tank slightly. You should not have to remove the oil lines. Take the battery cable loose from the starter and unplug the single wire at the solenoid part of the starter. Remove the two large socket head bolts that hold the starter on. When the starter comes off, there is a coupling that connects the starter with the jackshaft. Mark the direction it goes back in or make sure the counterbored end of the coupling goes towards the jackshaft. Reinstall the starter in reverse of these procedures.

Good Luck
Steve

That's because you haven't taken the starter jackshaft loose in the primary. Drain the primary and remove the outer cover. There's a small bolt that holds the jackshaft to the starter. Remove the bolt and your starter will come out. If the coupler falls off, put it back in with the starter with the counterbored end facing the jackshaft.

Good Luck
Steve

If your bike is a Big Twin, the starter jackshaft is held onto the starter by a small long bolt. To get this bolt out, you should have to remove the primary cover off the left side of the engine. If the jackshaft came out with the starter, the jackshaft was pulled through the oil seal in the inner primary. I've never seen this done. Go to http://www.bikebandit.com and look at the breakdown of your starter.
http://www.bikebandit.com/2004-harley-davidson-touring-road-king-flhr/o/m18489#sch616426

Good Luck
Steve

First, disconnect the negative battery cable from the battery. Then, drain the oil from your primary. Remove the floor boards, shifter or anything else you need to remove in to remove the outer primary cover. Remove the outer primary cover. Remove the small bolt holding the starter jackshaft in and remove the jackshaft. There is a coupler that connects the jackshaft to the starter motor. If it comes out with the jackshaft, mark it so that you know which way it goes back in. If you cannot get the jackshaft out. continue on and once you get the starter bolts loose, you should be able to work the jackshaft out. When you go to reinstall the starter, make sure you put the jackshaft back in before you tighten the starter bolts.

Now, on the right side of the bike, remove the exhaust system or whatever might be in the way of getting the starter off. Remove the bolts holding the oil tank but don't remove the tank. All you need is a little room that you get by lifting the tank up a bit. There are two large bolts holding the start onto the inner primary. Remove these two bolts and unplug the single wire going to the solenoid and the battery cable from the starter. Now, you can work the starter out from under the oil tank and off of the bike.

To change your starter, you'll have to disconnect your battery. Then, drain your primary and remove the outer primary cover. Bend the small locktab back and remove the bolt that holds the starter jackshaft on. Remove the starter jackshaft. There's a coupling that may or may not come out with the jackshaft. If it does, make sure you mark which direction it goes. It will come out, either with the jackshaft or the starter.

Now, on the right side of the bike, remove the exhaust system and anything else that might be in your way. Disconnect the battery cable from the starter. There are two large bolts that take a 1/4" hex key as best as I can remember that hold the starter on. Remove these and the starter will come off. Do not remove the small long bolts that hold the starter onto the solenoid. There is also a singe wire that plugs onto the starter at the top of the solenoid endplate.

Good Luck
Steve

Disconnect battery , remove the outer primary case, pull back the lock tab on the starter jackshaft, unbolt the retainer screw, then remove the two starter bolts from the right side, sometimes you need to loosen the oil tank mounts to get at these, slip the starter and coupler out as a unit, replace the coupler and jackshaft the same way they came out when the new starter goes in, install bolts , retighten the jackshaft bolt and bend over the retainer, install and fill primary case, connect battery thats it buddy