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So I tried replacing the starter and it's doing the same thing, half a crank then clicking from solenoid. The starter gear seems to be jamming in the ring gear on the clutch. Is the jack shaft supposed to have slopp in it? When I push on the starter gear it flexes around a bit. Could my issue be the jack shaft assembly? Why the same issue with a new starter? Once the starter gear ingages it just clicks, and doesn't return to running position.
Whoa whoa whoa the ring gear flexes around a bit?? No no no should be solid. Is it not pressed correctly with the clutch pack? Clutch hub nut loose?? Or are you saying it just flexes back and forth in its natural circular motion? Clutch pack/ring gear bearing shot??
Yes, starter Jackshaft can have some wiggle. When I replaced mine with the single piece All-***** one I was surprised how it wiggles. As long as the screw (bolt?) is torqued youre good there.
Ring gear is jamming the starter Jackshaft out??
A quick R&reinstall of the primary chain assembly and inspection may be prudent. Also, is the primary chain within specification on its travel? IOW is it running straight? (shims are used beneath the Compensating Sprocket to ensure the chain is running straight and not binding).
Rebuilding the primary is meat and potatoes as long as you have a big-*** torque wrench for the Comp Sprocket nut and a left hand torque wrench for the clutch hub nut.
The drop voltage test on the green wire was confusing.. Black test lead on green wire plugged in and red probe on +post. It read 11.7v without cranking and 4 v while cranking.
Please see below out of my manual. Sounds like you did the test correctly and have voltage drop in the solenoid circuit. (I think you tested the positive battery cable separately and had no drop, correct?) Make sure all connections are clean and tight. The circuit has several components as per the diagrams I attached.
Voltage Drop Test
Before perfonning the steps listed under Troubleshoot-ing, perform this voltage drop test. These steps will help find weak or damaged electrical components that may be causing the starting system problem. A multiineter is re-quired to test voltage drop. 1. To check voltage drop in the solenoid circuit, connect the positive multimeter lead to the positive battery termi-nal; connect the negative multimeter lead to the solenoid (Figure 6).
NOTE The multimeter lead must not touch the starter-to-solenoid terminal. Figure 7 shows the solenoid term.inal with the starter/solenoid removed to better illustrate the step.
2. Tum the ignition switch on and push the starter button while reading the multimeter scale. Note the following: a. The circuit is operating correctly if the multimeter reading is 0.2 volts or less. A multimeter reading of 12 vol.ts indicates an open circuit. b. A voltage drop of more than 0.2 volts shows a prob-lem in the solenoid circuit.
I got the bike started runs great. I got to thinking, and hooked two batteries up to the bike at once. I hit the start button and it fired up. Evidently the jumper cables I was using we're cutting down on the power actually getting to the bike. So with a fully charged battery hooked directly to the bike no jumper cables, it started. Don't know why I originally had a problem but somewhere along the way I corrected the original problem and didn't know it. It was strange that I wasn't getting a high voltage drop reading on the jumper cables themselves. Thank you everyone for all the help
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