I have a late evo softail, i had an issue with the starter clutch. Replaced it, and now it seems that 85% of the time, it does not kick out far enough. The other 15% of the time, it does, turns the motor over, maybe once, then kicks back, still spinning.

Battery voltage is 12.7 with a drop to 10.4

The starter clutch was installed and the mesurments were the same, as far as widths, teeth, etc.

any idea's as to what would cause this?

 

How do you know that the pinion gear is not going out far enough?

 

i can see it with the primary cover off.

 

If the starter solenoid plunger is not extending fully it may be caused by low voltage passing through the coils in the solenoid.

Check the wire that goes between the solenoid and the starter relay (terminal 87 on the relay) and the wire that goes between the relay and the ignition switch (it will be connected to terminal 30 on the starter relay), make sure those connections are clean and secure.

The relay itself could be the culprit, they are cheap and commonly available at any auto parts store, just ask for a 5 pin Bosch type relay.

 

I do not utilize a relay for starting. This is a very very stripped down bike, bare essentials. It uses a manual solenoid plunger for starting. I will check connections on the starter itself, on tuesday, bike is at work...

 

I guess I don`t understand why the solenoid plunger does not extend all the way out, if it is a manual plunger...