I have a 1990 softail. the problem is when I hit the start button there is one LOUD click but nothing turns as if the starter was locked up. I can loosen the mounting bolts and it will start. It seems like something is in a bind maybe. any ideas? Thanks

 

Would guess that the starter drive assembly is assembled wrong.

 

have you done anything to the starter, primary, or clutch basket? these questions need to be ask but my first guess would be to add a second relay to the starter to ensure direct power to the starter

 

Almost sounds as if the motor might be locked up.. Put the bike up on a jack pull the plugs and put the trans in 2nd gear. Then turn the rear wheel forward to see if the motor or primary is not locked up then get back to us...

 

OP has a softail and softails don't need a second relay.
All he has to do is run a 20 amp fused wire from the battery post to pin 30 on the starter relay.

 

Mounting bolts for what?

Is this a new problem?

Has some work been done recently on the bike?

How old is the battery?

 

What the hell was I thinking... Feeling like a DOH!!! moment...

 

Yes I had the inner and outer primary off to install a new belt. Replaced all seals, primary chain, shoe, installed bearing upgrade also. I'm know the engine is not locked up because it will crank fine if starter mounting bolts are slightly loosened.

 

Take the outer primary back off and reinstall it.
I recently went through something like this but I didn't try to loosen the starter bolts.
When you reinstall the outer primary make sure you go straight in with it, no angles or wiggling or anything else.
What I think happened to me and is happening to you is the starter drive gear is getting hung up trying to get into the bushing in the outer primary.

 

You didn't put the #31 coupling in backwards did you? There is a circlip inside of it the that if put in backwards I believe will not allow the starter to engage fully..