I've got an 88 Heritage that hasn't been run in two years.

Last time it ran the starter went out and it had to he push started.

I've been trying to get it to run. I've changed the starter, solenoid, and a new battery and recently came across a problem.

The solenoid can't engage the starter gear on the pinion. It seems to be in a bind somehow. I checked the magneto in the solenoid and it pulls hard.

But I think my shift lever for the starter gear is bent. How do I get that all apart? I can't figure out how to disassemble the plunger and shift lever to get the sucker out and fix it. But I don't think it's just the shift lever. The whole gear is hard to disengage and engage. Have you run into this?

I took video showing me trying to engage it, and then having to physically push it back to release. I don't know if that will help.

I know I'm a newbie here, and this probably looks like trolling for views, but really it's not. I'm just trying to get this bike working, and this is the only thing holding it up.

Any ideas are appreciated.


Pics:

 

I can't answer your question.. But you will get better response in the EVO section.

https://www.hdforums.com/forum/evo-classic-models-84/

 

Dang it! I looked for it, and must have speed read over it. Thanks man. I didn't mean to cross post.

 

They went out of their way to make this setup complicated. My first move would be to replace your wires with some marine type wire that is tinned and that is very fine strand and soldier and crimp the ends. Juice flows on the outside of the wire so the more strands more juice. Heavy duty sticky type heat shrink is good to. Use dielectric grease on your connections. Sounds like most of your parts are new and now with new wires now your getting all available volts. From my experience you need the outer cover on to make your gears mesh. There's enough slop in the starter shaft to cause binding. From the video your not getting enough juice to your solenoid though which should be corrected by the new wires and a hot battery. What condition is the relay in? I've replaced the POS plastic ones with the older mechanical ones with good results though the plastic ones do work if you get a good one. The solenoid should really bang in there. It will still hang up though without the outer cover because it needs that support. When you install the outer cover lift up on it when you snug the bolts. I know there's dowels on it but every bit of spacing you can get will assist in the release because that's a pretty light spring on the return. Be sure the brass spacer is on the end of the shaft between the cover and starter shaft. Good luck

 

What Snowyone said. The outer cover has to be on as that outer bushing helps align the starter drive.

 

Great pics . and thanks for that as it really helps us try to find the problem .
You said the starter has been replaced and as i look at the pics. it looks to me like the
pinion gear is refusing to mesh with the ring gear because they are not close enough to each other to engauge ???
Do you have the correct replacement starter/pinion gear size for your bike ?

 

I know if I've had the inner primary off and I've got everything ready to go except outer pri cover to put on I always give my starter a try to make sure all is going to work ok then put my primary cover back on so I have to say although primary cover bushing lines it up it isn't needed to make sure jack shaft is going to kickout and turn the ring gear.i would lean toward a low juice issue as well.

 

Let's tackle one problem at a time. First did you replace the spring inside the solenoid plunger??? If not the lever won't return. Next you need to rule out electrical dificulties. What type and how old are your cables?? What is the voltage drop and have you tested the battery with a load tester?? Remember where the solenoid bolts to the primary is a ground and needs to be squeeky clean. Do you have a ground cable going from the battery and starter/primary?? If all is well there then check ot the linkage to ensure it isn't binding or hanging up. Then pull all the starter stuff off and make sure the mounting points are clean because if they aren't then the ground for the starter could be poor or it might hold the starter a little crooked. Lastly make sure that the gears are well lubed. Hope this helps.
John