I replaced the primary seals on my E-Glide and now I cant get the starter to work consistently. I installed everything the first time and when I hit the starter button I got a "click" over and over about 5 times.

I pulled the battery and got it tested and it failed the load test so I got a new battery. Put it all back together and same thing with the new battery.

I pulled the starter and layed it on the work bench and it works fine (solenoid pushes out and starter motor turns) with the same battery.

Assembled everything and got the "click" once again.

If I pull out the pinion gear by hand and then release the gear (while its in the primary) it works and it will crank the bike over, multiple times in a row. But then when it sits overnight I get the click again. It seems like the pinion is binding in the new jackshaft seal, that's all I can think of anyway.

Anyone have any ideas how to remedy this, I need help with this one.

 

Check the starter relay. When they go bad you get the 'click of death'.

 

Starter relay is good, if I pull out in the pinion gear by hand and then release it (while the starter is mounted to the primary)the starter works fine and turns the motor over.

 

Did you open the cover to the solinoid? Once I over tightened the pos post on the starter and it rotated the tab in the solinoid and it was only making contact on one corner of the plate. Plenty to make it work fine on the bench but put it under load and nothing but a click. Just a thought.