1998 FSXTC Starting issue
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Stage II
Joined: Jun 2006
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1998 FSXTC Starting issue
Bear with me, I am a newbie here. I have some pretty good mechanical skills, built a couple of cars up, but never really did engine work. I know my way around things, and have been learning the terminology specific to the H-D world. I will try to be as thorough as possible in my explanation. Last season I went to start the bike up, and all I got was a "whirrr" sound. Since it was late in the season, I was holding off until this season to tackle it. I determined (easily) that the pinion gear was not engaging with the ring gear and therefore not turning the motor over. The starter was in fact turning, hence my whirr. I replaced the battery, it was the original from factory and after 8 years of service, I know that I was pushing it. Still got my whirr, only faster now. Last night I tested the starter relay, full continuity when energized. I began taking stuff apart (I am being simplistic here). Primary cover drained and off, ring gear pristine, pinion gear pristine, some resistance when manually pulling it out. Pulled off rear exhaust pipe, and jackshaft bolt so that I could remove the starter and bench test it, dang when they say sparks fly.. they are not kidding, anyhow.. I only got through the first test last night being it was so late.. but when checking the solenoid kick out, it kicked out HARD. I will perform the other 2 tests to check hold out and return, but my concern now is my jackshaft. Since I have never seen a good clean one, I think the splines are a bit worn on it (starter side) but am not sure. I have attached the best photo I could grab last night, I am looking for any and all possible routes to go with this.. any help is greatly appreciated, TIA.
[IMG]local://upfiles/13704/730F6D5A0FD84E3C8A0C155EF207056D.jpg[/IMG]
[IMG]local://upfiles/13704/730F6D5A0FD84E3C8A0C155EF207056D.jpg[/IMG]
Tourer
Joined: May 2006
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RE: 1998 FSXTC Starting issue
Are you following the factory service manual? Being a mechanic, I'm sure you know that you shouldn't tear stuff apart without the proper manual. 
Look up the starter in the book and see what it says. Personally, I don't see a problem with the splines. They are slightly worn, but should still engage fine. I may be wrong though, since I can't actually measure them with calipers from here. Go to a shop and ask to look as a new one, then you can compare them better.
Look up the starter in the book and see what it says. Personally, I don't see a problem with the splines. They are slightly worn, but should still engage fine. I may be wrong though, since I can't actually measure them with calipers from here. Go to a shop and ask to look as a new one, then you can compare them better.
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Stage II
Joined: Jun 2006
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RE: 1998 FSXTC Starting issue
Thank you Spectrexx, yes the factory manual.. lol.. I rarely tear stuff apart without knowing some iota of information about it.. lol.. but I have done it. I have been spekaing with a local dealer, good guys very helpful, about this.. and without me describing the sound, or him hearing it.. but giving some information, he described the sound, said that a low battery or bad connection at some point (which I had a while ago) could be indicative of the overrun clutch failing. When I thoroughly read teh whole starter section and starting systems section I did suspect it, but was following troubleshooting and trying to do it methodically. Thank you for looking at the photo and squashing my fears. Some of the aftermarket/replacement jackshaft photos I have seen show larger more defined teeth, and the schematic drawing in the shop manual is not really detailed enough to be sure.
Tourer
Joined: May 2006
Posts: 458
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RE: 1998 FSXTC Starting issue
You would be amazed at how many posts I see where people are asking how to do something that is clearly stated in the service manual. They just don't want to spend the measly 50 bucks so they can properly work on their $10k+ motorcycle. Then they wonder why things start falling apart. People with no common sense or mechanical ability should not be touching tools, IMHO. If ya screw something up, your life (or someone else's) could very well be in danger!
Yes, a weak battery or loose/corroded connection can cause it, too.
Yes, a weak battery or loose/corroded connection can cause it, too.
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