Whenever I try to start my bike the bendix gear wants to stay out. Then the solenoid starts to get hot. I've tried shims,no shims. The bendix gear,shaft and starter housing and solenoid arm are all new. Any ideas would be appreciated.

 

low voltage on the bat can cause this problem

 

It is probably from low battery condition. Mine will do that too if the bat is low.

 

Is the roll pin installed for aligning the inner/outer primary covers? Sometimes the holes for that pin are worn. Try holding upward at the rearward end of the outer cover as you tighten it up to get the starter shaft moved up slightly; it could be the gears are pushed together too hard from the outer cover "sagging" down a little. If the pin is missing, a piece of 1/8" welding rod cut to the proper length will do.

 

Also, make sure all your ground wires are clean and have a solid connection. A bad ground willl act the same as a weak battery.

 

You said the starter shaft was new. If you put any lubrication on the worm threads that the starter bendix (pinion gear) rides on it may cause it to stick.

 

Thank you all!! you have given me some good ideas to try. Appreciate it hope I can help you on a problem sometime.