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I have a 2003 Softail with less than 4,000 miles.
Starter engages, but the shaft does not spin. Solenoid contacts has been replaced and the armature has been turned at a starter repair place.
I can't find any diagrams for parts that show me how the starter engages to the jack shaft.
Any suggestions would be appreciated.
Thank you for your help.
Re: I have a 2003 Softail with less than 4,000 miles. ...
If your starter clicks and you can hear the starter motor spinning but the engine is not turning over, your starter clutch, sometimes called the "overrunning clutch", is bad. Try this site for your starter breakdown. http://www.bikebandit.com Click on OEM parts, find your bike, and look under electrical for the starter.
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I remember on several Toyota Corolllas, the starter solenoid would throw the contact plunger back and make contact from Battery to Starter before the Pinion gear on the starter shaft was fully engaged with the Flywheel Gear. Check for wear on the actuating fork pivot point (Bearing), that throws the gear to the back engaging the ring gear on the flywheel, and makes the contact plate short the terminals to provide current to the starter motor
Most starter relays are part of the starter motor assembly.
Also known as the solenoid.
(This way it serves 3 purposes.
1. The Relay section uses solid copper Contacts for Less volt drop at the high current that a starter motor draws.
2. The Solenoid section is the Mechanical Plunger that engages the cog to flywheel.
3. The Motor spins because the copper contacts are a super connection supplying 100+ Amps)
Does the battery go direct to the Starter Mptor?
Is there a small wire next to where the Battery connects?
If so then this is the relay activation wire (12v to pull relay in)
Happy Starting
External Relay Basics
Same but bigger for Starter Motors RELAY BASICS
Check the website for Autozone to get wiring diagrams free. If starter spins but doesn't engage, it is a bad starter drive located on the shaft of your starter. The solenoid is only there to spin the starter on a Ford. The centrifugal force engages the starter gear.
Your late model bike does not have a Bendix like the older bikes. Doesn't have the conventional solenoid either. It has a Nippondenso type starter. The solenoid is actually part of the starter assembly. Instead of a Bendix, it has what is called an "over running clutch" that does the same thing as the Bendix. Basically, it's a one-way bearing or sprag unit. It is inside the starter assembly and to replace it you must disassemble the starter. The symptoms of this going bad is you'll hear the starter spinning but the engine will not turn over.
Now, if you're only hearing a click and the starter is not spinning, you may have to replace the electrical contacts inside the solenoid. They're are easy to replace. Just pull the plate off the back of the solenoid by taking out the tree small 3mm screws. Pull the plunger and spring out and you'll see the large copper contacts. Harley and aftermarket manufacturers offer the replacement parts kits. The job can by done without taking the starter off the engine most of the time.
If you are saying that you have replaced the starter motor and the solenoid and checked the springs and the starter drive fork and found the in good condition, let's assume that all this stuff is good. There are a few more things left. One is the ring gear of the outer clutch drum. Inspect it for damaged teeth. If that is found to be in good condition, the starter drive (Bendix) may be bad. This is the gear on the end of the starter jack shaft that has the one-way bearing in it. Sometimes they go bad and allow the shaft to slip inside the bearing. The starter spins but does not turn the engine over. The starter drive can be replaced by removing the left handed threaded nut off the end of the shaft.
If you don't think this is the reason for the "jumping out", the solenoid windings create a magnetic field that pushes the starter out to engage the ring gear on the clutch outer drum. This also holds the starter gear engaged. If the starter gear is jumping out, the solenoid could still be defective.
The only other thing I can think of is that the engine may be trying to start just enough to disengage the starter but not well enough to continue running.
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