electrical 67flh stock
Road Master
Joined: Jun 2008
Posts: 1,078
Likes: 39
From: NW Florida
On the pre 70 models there is a thrust bearing on both ends of the shaft. The large one that is against the bearing in the other primary and a smaller bronze washer at the other end against the bearing in the starter gear housing. If it is missing look for it at the bottom of the housing, it may have fallen and is jamming the gear.
Cruiser
Joined: Apr 2011
Posts: 188
Likes: 17
From: SE Pa.
Pull your primary cover and check the parts underlined in the pic below for excess wear or broken teeth. Also check the teeth on the starter ring gear on the clutch shell for excess wear or broken teeth. Possibly if any of these parts aren't meshing properly it could be causing your starter to bind and overloading the circuit breaker. 
Seasoned HDF Member
Joined: Nov 2006
Posts: 12,878
Likes: 5,449
From: la la land jerzey
first step back a second and just start over an issue is causing you stress and you are over looking the problem
when we assemble a starter and its works you can check it like this
remove battery ground - remove the solinoid than - the piston it works is not in the parts picture above BUT if you hold the starter end nut and push the piston that sticks out of the inner primary under the sol in and out, the sol piston if its binding than thats an issue it should be free to move back and forth easy
than take the starter gear nut again with an open end wrench and walk the gear in a circle and it should be free ( now its turing all the gearing and the starter so it will be stiff to turn BUT free from any stopage / binding or lump spots so to speak )
if you have got this far and all is as explained than you need to dissasemble the end cap of the solinoid and look under it and see if the contacts are burned off or worn out - if you have a china unit than all bets are off to how long it would last or how good it might be - sure the starter brushes could be an issue but you had it checked by a shop soooo we need to go back to the one other part in this and that is the soloniod -
i have seen brand new china soloniods short out in just a few days from what china calls new so -- jz
when we assemble a starter and its works you can check it like this
remove battery ground - remove the solinoid than - the piston it works is not in the parts picture above BUT if you hold the starter end nut and push the piston that sticks out of the inner primary under the sol in and out, the sol piston if its binding than thats an issue it should be free to move back and forth easy
than take the starter gear nut again with an open end wrench and walk the gear in a circle and it should be free ( now its turing all the gearing and the starter so it will be stiff to turn BUT free from any stopage / binding or lump spots so to speak )
if you have got this far and all is as explained than you need to dissasemble the end cap of the solinoid and look under it and see if the contacts are burned off or worn out - if you have a china unit than all bets are off to how long it would last or how good it might be - sure the starter brushes could be an issue but you had it checked by a shop soooo we need to go back to the one other part in this and that is the soloniod -
i have seen brand new china soloniods short out in just a few days from what china calls new so -- jz
Last edited by johnjzjz; Apr 9, 2013 at 06:37 AM.
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Cruiser
Joined: Jun 2008
Posts: 131
Likes: 0
From: south bend, IN
thanx
hey. I'm back on it.. it seems I only get a chance every now and then with my too hectic schedule. (oh how I miss the "my bikes are the #1 priority" days).... hey, wondering.. I am about to take the starter shaft housing apart again.. figure I might wait to hear from ya here... on my housing.. I have pressed in needle bearings.. check. NO thrust washer?! UNLESS.. it is part of the housing almost? the housing has a raised circular almost embedded washer right where the thrust washer goes. Is that it? Or am I missing it?
while I am at it, the thrust washer on the outer primary side is thin. Does it NEED to be a certain thickness? I have heaqrd some say the shaft never really gets out there anyway, I dunno, I always just looked at it as a washer, but if tolerances are pretty important here, I'll replace it as I am gonna try and get an order together.. On the solenoid. I think Ill just replace it. I have heard accel's are no good. Is Harley any better? whats the best..... measured my cables and there in the order!
while I am at it, the thrust washer on the outer primary side is thin. Does it NEED to be a certain thickness? I have heaqrd some say the shaft never really gets out there anyway, I dunno, I always just looked at it as a washer, but if tolerances are pretty important here, I'll replace it as I am gonna try and get an order together.. On the solenoid. I think Ill just replace it. I have heard accel's are no good. Is Harley any better? whats the best..... measured my cables and there in the order!
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