1967 FLH. Went to start the bike the other day and starter just spun. Pulled outer primary to check solenoid, Bendix operation and everything looked good. pulled on Bendix to check and shaft was loose and starter gear was moving around. Pulled the starter to check gear and needle bearing. Turns out that the shaft had backed out of the starter gear so motor was spinning because it wasn't engaging anything. My question is how could this happen? If one end of the shaft is in the needle bearing of the starter housing and the other is in the bearing in the outer primary, how could the gear come off of the shaft? Nothing looks damaged, splines on shaft and gear look good. Should I replace the shaft and or gear or just put it all back together? Found out that the oil deflector and O ring are missing so I have to order those parts anyway but wanted to tap the brain trust about replacing the shaft and or gear or both. Thanks in advance.

 

 

Possible the washer (#16) dropped during assembly at some point or wasn't in there, that'll give you a lot of free play on the gear engagement. Make sure you have it all the parts, carefully reassemble everything and go, only seen one bad starter shaft in 40 some years dealing with these things and it was the other end had issues.

 

You're spot on Twisted. I have a parts book but didn't notice that the washer was missing along with the oil deflector and O ring. I wonder if if I'll ever get to the point where I've worked through all of the screw ups of the PO. Luckily so far nothing has left me stranded. They've all happened in my own driveway. Thanks to all.

 

james make a conversion plate that uses no o ring as the plate is rubber and the hole for the starter shaft, is a seal type lip = works real well

 

Thanks John. I'll look into it. The PO did isolate the primary and installed a belt primary so the primary is dry.

 

Reason no o ring was installed = you wont need it

 

I think you're giving the guy credit for knowing what he was doing John. I think he just left some parts out. It's just another chapter in the saga.