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Ok so I have a 06 fxdbi it has the newer style big twin starter and recently it will spin but not engage
I bought a solenoid rebuild kit and installed it but it didn't fix the issue
I found out thru my hours of tedious investigating that the plunger return spring is weak and no longer applying enough pressure to engage the starter clutch
I also found that you can't buy the spring anywhere I have seen
so my question is does anyone know where I can get one new or used so I don't have to blow money on a new starter?
The solenoid is what pushes it in. Spring only pushes it back. Sounds like your battery is worn out and may have good voltage from a charge but no amps. Or you did not get it back together correctly.
The starter clutch is actually a sprag clutch. It has pins that drive going forward. If say it's running and you keep starter button down with gas motor running, gas motor outruns sprag clutch and runs the sprag rollers up the ramp to disengage.
It is possible to break this but it rarely happens.
However, tin men on here start threads like this to sale their parts.
If your thread is not that, I can get on my computer and post some pictures if you need a better understanding on this. Let me know.
Last edited by Jackie Paper; May 6, 2018 at 05:57 PM.
Reason: spelling
YOUR STARTER AND Solenoid itself need rebuilding because not enough amperage is being utilized ( from your battery ) thru your Solenoid to turn your motor over . A Total rebuild and an increased KW ( Kilowatt) charge is needed to crank your motor over . Is it stored in a cold climate...? Has It Been on a Trickle Charger over the Winter months in a warm storage climate arena( Garage or otherwise ) ? As far as a *STOCK* H-D Starter theres not much more choices in a higher kW starter motor or complete kit unless it's a H-D Bigger C.I. Starter( which are junk to be honest ) . A Company Called *TERRY COMPONENTS* makes many Starters and solenoid complete kits to alleviate your starter woes Forever. They are Pricey: But GOOD WORK IS NOT CHEAP & CHEAP WORK IS NOT GOOD . I'd First ten go to see if H-D can rebuild and help you (Doubtful ) then investigate and talk to REAL Company's for the solution to your starter needs and necessities.
Sorry But This is the only closeup I have of my *TERRY COMPONENTS * Solid Billet 3kW starter.....but this is also a 150 C.I. S&S Anniversary ENGINE - so you wouldn;'t need such a heavy duty starter with that much KW output........i'm not certain if H-D offers a rebuild kit for your needs,but it's worth investigating and asking a real service guy @ H-D who is at least familiar with Starters and the options to rebuild yours at a decent price and Guarantee their work . Good luck and lemme know how you make out .
Vince
I have a brand new sealed agm battery brand new starter clutch brand new armature and brushes and now a new solenoid kit installed I guarantee this is not a voltage issue the return spring is weak and part of the coils on the spring are permanently compressed I added a second ball bearing to make up for the gap and now the bike starts properly however I would like to fix it right
How it works. See the spring on the right side of the solenoid and up front, that pushes it back. What I said about battery was just my first thought impression. Not that it had to be that. From what you describe about spring broke and adding a ball makes no sense. Must be non OEM. Sounds like you need a complete starter. Tin men carry on...
Last edited by Jackie Paper; May 6, 2018 at 06:27 PM.
I assume you are talking about the bigger spring fwd of item 12. Looks like 3 ***** in the top attachment and when engaged, they are together. That is a spring. Also shown layed out in lower pictures. When you hit the starter, it powers solenoid is an electrical magnet that pulls big contact in that powers heavy amps of starter and spins starter. The helix of the gears pulls it fwd. When you cut power, springs push all back. And Welcome from Hampton Roads Virginia to the Forum
Last edited by Jackie Paper; May 6, 2018 at 06:39 PM.
I was looking at your picture in your user.. Guess you are referring to that thrust ball 9. But all those spring push back. My guess is you cannot replace the damaged spring with a part number that they sell, you need a starter. Which spring is damaged? By adding a ball, you are driving all out. Not a good idea.
Last edited by Jackie Paper; May 6, 2018 at 06:46 PM.
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Starter question
