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Take the cover off the solenoid, see if the jack shaft moves in, looks like the collar is still not all the way in, I think it should be about flush with the bushing in the inner primary.
It should look like your last picture in post # 46
The coupler is installed with the counter bore facing out, away from the starter?
Take the cover off the solenoid, see if the jack shaft moves in, looks like the collar is still not all the way in, I think it should be about flush with the bushing in the inner primary.
It should look like your last picture in post # 46
The coupler is installed with the counter bore facing out, away from the starter?
Thanks Schex, yes I need to reopen it again...I did look at it before and thats when I found the new "button" cover I'd put on was stopping the the shaft from moving all the way back but there still seems to be a fraction left. I also want to have a look at the coupling and make sure there is no small spec/particle stopping the splines from going all the way. In the photo you mention it is absolutely all the way in so I know it can go in that far! Fingers crossed!!
There is a circlip in the coupling and it is offset, regardless of any other clues to it being in correctly, have you checked it is offset the right way and not stopping the dog from pulling back in far enough?
Other than that, last week I saw a solenoid that was all messed up and the contacts were holding the solenoid plunger in and not letting it release properly.
Morning gents.
I have removed the starter and opened the solenoid and checked the shaft is full in. Everything is good, its all moving, nothing is getting caught on anything and as far as I can try, I cannot push the collar with the spline in any more - see photos of spline one and with the coupling on. To my mind the starter/solenoid is fine and I can do no more adjustment.
The couplings are all checked and the offset circlips are in place. With the coupling that comes off the solenoid I have checked and double checked that the "longer" inside shaft goes on to the end spline of the solenoid and the "shorter" end of the coupling connects to the jackshaft. I have also checked the direction of the other larger coupling.
Without the starter I can push the collar of the jackshaft into the inner primary bushing all the way flush. Once I tighten the start into position and connect the couplings I am out by a fraction. I cannot get any change to this other than loosening the starter.
I have adjusted everything I can and cannot find that extra 1 mm!!!!!!!
I am going to place a small thin washer on the tip of the jackshaft which should push the starter cogs back in by 1mm - that is all I can think of at this stage - I may be going "wrenching blind" now but I cannot find any other solution. FYI I haven't torqued everything down when I've been dry fitting it but I've tightened things down quite a bit so I don't think this will make much of a difference to the overall fit.
Last edited by monchidog; Feb 26, 2025 at 03:34 AM.
Weel if you can get everything flush with the starter out then there is something wrong that you did with the starter. Putting an extra washer on the very end will not improve anything..
Weel if you can get everything flush with the starter out then there is something wrong that you did with the starter. Putting an extra washer on the very end will not improve anything..
Absolutely 98Hotrodfatboy there must be something in the starter end of things that is misplaced by a fraction. Basically this end bit circled in red simply cannot be pushed in. I am not comfortable opening this end of the starter and seeing what's in there and whether something inside has shifted but maybe I have to - I'll look up some you tube videos on what this entails.
Is there a seal where the starter connects to the inner primary...I dont think so?
On the starter all I did was clean it.....open the back cover of the solenoid, clean the copper connector tabs and put on the new "Button" cover - nothing more.
Yankeedog.... here is a photo of the seal which I replaced but again..pretty sure it is correct with the "spring" side in towards the oil in the primary.
Like you guys I am running out of ideas. This is the first time in 7 years (since I've had the bike) that the Inner Primary has been taken off so perhaps this has indeed put something out of whack? While I wait for the Case Saver gasket (next week sometime) I'll keep having a look and see what I can check.
No, there is no seal between the starter and the inner primary. However take the button off the back of the solenoid and reassemble everything and see where your opinion sits at that point. In other words leave the back of the solenoid wide open..
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