Ive started a new thread specific to this one issue. The rebuild of the 74 FLH is coming well, but the starting circuit is not. I have replaced the solenoid new, and the starter relay as well. I know the wireing is now correct but when I hit the button the starter spins but the solenoid does not always kick in and the starter spins. I thought perhaps a new solenoid would fix that but it didn't then I did the relay as well. What do I look for now. When the solenoid does kick in, the starter spins the motor well but it will take two or three tries with the button. Relay is grounded and so is the starter.

randy

 

the starter gear that drives the clutch hub is called the Bendix gear - the original has a 3 ball clutch in it / the after maket HD unit has a 5 ball clutch in it --

when its worn out it skips / sometimes the gears clash / than cranks the engine and clashes again

sometimes it just sping and does not turn the motor over at all -

its the small gear at 12 oclock inside the primary above the clutch drum

a USA unit will give you the best service life and they are the 5 ball type BUT not all 5 ball are USA made - johnjzjz

 

What is the condition of the ring gear on the clutch hub? Are the teeth mangled? This is usually the result of a bad bendix gear. Remember if you replace this gear, no lubrication on the worm gear that it rides on.

 

ring gear is ok. Can I change the bendix gear without pulling the starter or cluctch basket?

 

You don't need to remove the clutch basket. I usually remove the solenoid to take the tension off the bendix shift lever. Some people just wiggle the shaft loose from the finger. The idea is to not distort the o-ring seal at the rear of the shaft. The spacer nut at the end of the shaft is left handed thread if I remember right. Don't scar it up, clamp it in copper jaws of a vice to unscrew it. There is a snap ring inside the collar that holds the gear in place.