Last weekend I was just running a quick errand on my 98 FLHTC and when I came back to the bike, tried to start it but all I got was a "whirling" sound. So after several hours of messing with the bike and a free HOG membership tow, I got the bike back home. Looking up thru the derby cover I could clearly see that the pinion gear was spinning but not coming all the way out onto the ring gear. So I tore the starter out and took it to a shop that rebuilds starters and alternators. All the bushings, windings, and bearings looked and tested good, but the plunger in the solenoid needed replacement. So 65 bucks later I have my starter back and I put it on the bike. I inspect and clean the connectors and add a dab of dialectic grease. So now I test the starter, the pinion gear comes out and sits properly onto the ring gear but will not crank the engine. Now I'm thinking bad battery tho it is only 2 years old, so I hookup my 200 amp car charger to give it plenty of voltage and still it just comes out and sits on the ring gear and will not crank the motor. I'm stumped. Did I install the starter wrong onto the jackshaft? Or did install the pinion gear incorrectly? It all looks like it is working properly so I'm at a loss here. What else could it be?

 

Check to see if you have 12 volts right at the starter when you hit the button. If you do, you should be wired correctly and have a bad starter.

If not, you have something miswired.

 

When the starter engages, does it look like it's "trying" to turn the ring gear? Do you see it putting tension on the primary chain?

 

No, that's what is so weird. The pinion gear just slides over nicely but doesn't turn the ring gear at all. It don't look like it has any power what-so-ever.

I will check the voltage at the lead when I get home.

The guy at the starter repair shop said to try hooking up another battery, thinking I may have a bad cell or bad battery. I'll try that tonight

 

A friend of mine had the same problem.
Installed rebuilt starter and nothing.
Then he installed a new starter and it worked fine.


I have no idea why it worked out that way but it did.

 

Then that's really good news, as it rules out (for the moment at least) something really bad like a seized engine.

Assuming the repair shop you are using is competent, it almost has to be voltage. They bench-tested the starter after they did the repair, right?

I'd be looking at the battery, the connections, and the ground strap.

 

Juice isn't getting to the windings in the starter to make it spin.
I'm betting it's in the starter.
Give the place a call that did the rebuild and ask for some help.

And resist the urge to jump start at 200 amps Thats a bit much



WP

 

The mechanical part of the solenoid is doing it`s job, because the pinion gear is being extended into the ring gear.

It may be that there is a problem with the electrical contacts inside the solenoid.

Disconnect the battery, pop off the end of the solenoid and take a look at the two electrical contacts and the plunger, make sure they are contacting properly when the solenoid plunger is extended.

 

Had this issue on my Heritage found it was the starter clutch, which is not in the starter motor, pinion would engage and not spin but the starter did
Part 36 in the attachment, hope this helps

On this webpage http://partsfinder.onlinemicrofiche....KCASE-ASSEMBLY

 

Assuming you don't hear anything spinning, Dan would be correct, solenoid is engaging, starter armature is not getting power to rotate via a faulty connection. Even if the armature is ready to **** the bed it usually will make a poor attempt at trying to turn the motor.