I hope someone can help. I just bought my 5th HD, been 15 years since the last one. Im having problems with the starter. Its a 79 shovel, 4 speed, closed primary. When i hit the starter button the starter hits real hard and dont turn it over. When it does turn it over and the starter shaft backs out it makes a real loud noise, sound like a fist full of gravel in the primary. I just took the primary off today and it looks like the thrust washer has been ground on with a grinder, who ever had it before me. It looks like the starter drive is hitting the back of the clutch basket because it has scare marks on it behind the starter gear. New starter, starter slionoid, new battery cables, wires. I guess what im asking is if the thrust washer has been ground on would it let the starter drive come out to far to allow the starter drive to hit the clutch basket? Looking at it, it seems that if the starter drive came out to far it would hit the clutch basket and lock the starter and then grind when it backed out. Any help would be great. Its been awhile since i wrenched on one and my buddies are giving me hell about it, so i need to wrench it back together.
Thanks in advance,
Warrior

 

From what you say here, it sounds like you need a new starter drive. It's not throwing out quick enough and spinning before it engauges with the clutch basket. That's usually what causes what you describe above.

 

Going to pick up a starter drive, thrust washer and siloinoid arm tomorrow. Gonna be a pain because the bolt that holds the arm that goes through the top of the primary is under the horseshoe oil tank, so that has to come out. But might as well replace it while im in there. Thanks for the help and if anyone else knows something that we are missing let me know.
Thanks
Warrior

 

Well found part of my problem. Someone before me put a aftermarket primary cover on it and where the thrust washer goes was to far from the starter drive using only one washer. So to fix it I had to use 3 yes 3 thrust washers to keep the starter drive from coming out to far and hitting the clutch basket and ring gear. I know it anit right but it worked. Now that is fixed my next problem on the list. Starter is suspose to be new, a Hitatchie jap starter. It is dragging real bad, turns over about 3 times then thats it and ya have to let up off the button. So the starter is out of the bike now and in the morning going to the elec shop to have it checked, hope like hell that is what it is, im running out of ideas. It has to be the starter, i have replaced everything else! Oh well, gotta love these ol shovels, not to many of us left out there these days. Well i will update ya all when i get it figured out.
Later
Warrior

 

Ok, I replaced the starter, other one was fried. I still does not turn over like it should. I tried it and at one point I heard the starter free wheel a couple of times. Well this anit right. I pulled the starter again and also took out the starter housing, starter shaft, gear, starter drive. It all looks good except that there is a little play on the starter shaft gear that goes to the starter. I turned it around and it tightened up a little on the shaft. I hate to put it back together if the starter drive is bad. Is there anyway to check it??? It seems to lock up alright one way and then freewheel the other. Also should there be any gap between the primay cover and the end of the starter shaft where the thurst washer goes?? I have to use 3 washers because of the after market primary cover but not enough room for a 4th. Also, is there a washer that goes between the end of the starter shaft and the starter housing, in a exploded view diagram it shows one but there was not one in mine when i took it apart? This thing is killing me and the cash flow is getting lower and lower. If someone can help me with this it would be great. Im real close to putting it back together and taking it to our local shop and just telling him to fix it. I hate to have someone else wrench my scoot but I'm about at the end of my smarts on this one.
HELP
Warrior

 

Do you know if it has an aftermarket inner primary? It doesn't sound right with the amount of thrust washers you're using. It could be an alignment problem with the inner primary if its an aftermarket one you might want to try Ebay for an original unit as most of the cheap replacements are trouble.

 

Hey I got it fixed!!! TDSTD nailed it right on the head. I took out the new starter, starter shaft, starter drive, starter gear, ect. My starter drive was my problem along with the fried starter. I repaced the starter drive and the gear that goes in the starter housing today and walaaaa, IT TURNS OVER. Starts like a new one now, and thats a good thing cause I was about at the end of my rope. Now all i have to do is get my clutch adjusted right and look out, one more ol shovel hardtail on the road. THANKS for all the help on here, you guys are great and I look forward to talking with ya again, just hope its not because of a problem that I cant get figured out............lol.
Thanks again
Warrior