So I've had a basket case of bike with my 1999 FXR3. Everything on it is aftermarket, so getting everything to work together has been a very difficult process. From primary problems, to exhaust mounting issues, to now, a starting issue. Here's the diagnosis...

The bike was having a hard time starting, so obviously, I checked grounds, battery, starting voltage..all the easy quick fixes you might have. I determined it was something in the starter. I have a S&S 113 EVO, and some info I've seen says that particular motor eats stock starters...no biggie..I've changed a starter before. So this time around I dished out some cash and went with the Spykes High Torque starter. We start working on it yesterday, and amazingly the starter goes in with no real trouble. That should've been my first hint! As we were installing it, there's this metal sleeve coupling that connects the starter to the jackshaft. My buddy who has been doing this forever said, "hmm..that looks a little short." Oh well...we installed it and did the "lets fire this baby up!" thing...CLICK! F#@%!

So...we check wires, grounds, all our connections...read the instructions..I mean we do everything we can think of! We have a sneaking feeling something is wrong in the jackshaft..It seems to bound up, and the spacing from the starter pinion to the clutch basket is a little wide. We pull out the bolt holding everything together and we do a little test with some rubber hose. That jackshaft should be getting kicked out to engage the clutch. So my buddy puts some pressure on the jackshaft...nothing...releases a little pressure...and BAM! That bastard flys out and engages in the clutch..So what we're thinking now is when we tightened the jackshaft, it was binding it too tight and it wasn't able to properly engage the clutch.

So we busted out the old service manual and there is a part number (obsolete) but does anyone know the proper length of that coupling? Attached is a picture of the service manual, and the part is #31.

Thanks for your help..I'd really like to ride this bike sometime this century...but it's proving to be a daunting task.

 

nobody here has any idea??

 

No idea but you posted in exhaust section, may get more views in electrical or engine maybe.

 

UH OH check the voltage of the battery, and check connections/grounds. Isn't there way way to bypass the ignition switch and jump it at the starter? That would eliminate the ignition switch and relay part of the circuit. Kind of like jumping a solenoid on an old Ford, but I wouldn't use a screwdriver, maybe a start switch or something. If it cranks then, you know the starter and battery is good.

 

I think there is only one length for that spacer. It CAN be installed backwards though. It’s been a long time but I believe the beveled end goes toward the starter but, please check your service manual for proper orientation.

 

Yup, theres a circlip in the middle and its not centered in the coupling.

 

Thanks for all the replies! Don't know how I posted in the exhaust section! Sometimes I get to punching away in the morning before I've had my coffee!

I did check all cables and grounds, that wasn't the problem..The problem seems to be in the jackshaft. When I tighten the long bolt part #6 in the diagram I think it binds the jackshaft down. I have seen there are shims I can use to space it out..The pinion gear should be about an 1/8" away from the clutch basket, and when everything is tightened it looks like it's about 3/16"-1/4" . I was thinking about just getting a new jackshaft from Spykes. They look to be only $100. The only drag is, I had to remove the clutch to get the jackshaft out. I have a 37T Baker 9 plate clutch, and I think the diameter is a little bigger than the stock 36T.

I swear this bike has ghosts sometimes...

Mods if you can, move this thread to Engine please...