Just picked up an 88 FLHTC earlier this week. It has a slow crank issue, even though all the starter, solenoid and battery were new, and also has a pretty good leak from the back of the inside primary cover.

So I opened up the primary today to source both the starting issue and oil flowing out like beer at a kegger. Found a couple of interesting things.

Clutch is toast, figured as much with the release being near the end of the throw.

Oil issues are related to two things, the solenoid boot/seal were completely shredded. Second is a little more complex, the previous owner had resealed the primary, but also at some point had replaced the needle bearing in the outer cover with a very crudely made brass bushing, this bushing (and lack of thrust washer on the starter jackshaft) were likely what was causing both my oil leak and the starter drive gear to rub the ring gear when starting. I don't think the oil was helping the inside of the solenoid much either.. The bushing being off center was also causing the primary to leak through the jackshaft seals, directly onto the belt.

Is it common to replace that needle bearing with a bushing? Or was this just a case of install what you can find in the garage? (I have made many brass bushings in my time)

 

Later models use a bush...no idea when this changed or if they ever used a neede roller.

 

Needle bearing in my '76 FXE...can't say what is in the newer bikes.

 

Parts manual for an '87-'90 shows needle bearing thru 1988, bushing in 1989. I'd hazard a guess that they've been bushings ever since.

 

In 89 they went to the Nippondenso starter, I took a look at that bushing anyways and its way thinner with a far smaller id. Since the denso starter is such a different animal than the earlier starter, the outer cover bushing doesnt see near the loads.

 

I guess the other thing I am worried about here is if the previous owner hogged out the hole in the cover to accommodate his home made bushing. I will have to wait till the bearing that I ordered comes in to see if I have problems there.

 

Think positive dude :-)