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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.
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.
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.
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1979 FLH bendix problem
