Tried the extra ground this morning to the starter, but no luck. Still the same. Drained primary and pulled it but didn't roll it. Yet had to run to town. Monday gonna pick up a new gasket and fluid. Dr. Hess will get back to you with the readings, put the battery back on charge after this morning. Gonna roll it over with primary cover off and plug wires disconnected so I can rule out the internals once and for all. (Even though they are new)

 

Didn't read the whole thread, but try this if you didn't already. When it works just Laugh and laugh and laugh.

Open the primary, find the fork that engages the starter gear to the ring gear on the clutch basket.

Reach in there with a pair of pliers and bend the little fork ends that ride in the slip ring to move it closer to the starter ring. Make sure there is still enough room to clear when starter is not engageing the starter ring.

Alternately, the pin in the solinoid return spring is in the wrong hole, in front/back of the washer or the rubber/grease in the solinoid is binding the inner workings of the mechanism.

Hope this helps

 

Starter clutch may be bad. Rolled it with primary cover off and foot on end shaft starter clutch came out and engaged but will not retract. Also ring gear (new) hes teeth chewed up on motor side, metal pieces in ATF fluid. So long posting cause J&P sent wrong starter. Will order a better ring gear and clutch and see what happens.

 

Thanks for the update. Keep us posted.

 

"So long posting cause J&P sent wrong starter."

that's not surprising...they've sent me wrong parts in the past...they're customer service is really good, but don't expect to get one of those 'techs' they claim are at your disposal because all they'll do is look up the part according to your scoot and argue that it must be the right part

you gotta go right to the manufacturer of the part to get info on proper application... don't rely on J&P to do it for you

 

Have a question. Do the Starter Solenoids with 2 tabs (not 1 tab w/2 bolt holes) require a spacer plate? The Diagram I downloaded shows a plate (w/2 holes?) behind 1 of the tabs. http://www.bikebandit.com/1988-harle...1401#sch184924 part #102. I know it will require 2 of them if needed. Looks like the solenoid is not pulling in enough and starter clutch is eating up the ring gear. Thus the chatter and grind.

 

A solenoid has to set "square" where it bolts on to the primary or you will have problems.

 

Yes know that, but is the shim a required (stock) item that the PO could have not put back on? This one would take 2 shims one on each side. The Starter clutch is catching the ring gear on the bevel. If it was running in 1/8" or so more it would fully engage and solve my problem. May do as other post says and bend the fork a little to make up the slack. But I don't like to bend something like this (cause a bend weakens the metal). But don't think a bend this small will hurt it.

 

I had the same problem with my '87 Evo, finally it won't start at all. Ended up replacing the starter clutch.

 

Starter clutch is new. Just seems like solenoid in not pulling in the clutch fork all the way. If it will travel in a little it will roll over.