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I replaced the OEM starter with an All ***** 1/4kW. I've done the same upgrade on a couple Sportsters (same 1.4kW All ***** starter) and never had any problems. This time the Bendix (one-way, overrunning clutch whatever we call it) won't retract properly and stays caught on the ring gear. Not every time but most times.
I can work the system by hand and the Bendix snaps back fine. But if I twist the shift lever all the way so that it collapses the solenoid spring completely the Bendix hangs. I tried varying the thickness of the thrust washer(s). I removed the starter a few times, re-installed it and the alignment looks correct. I cleaned up the OEM solenoid and it tests out fine.
Is it possible the 1.4kW starter is too strong electrically? I never heard of that but at this point I'm reaching ... of course All-***** recommends buying their "heavy-duty" solenoid to pair it with their 1.4kW starter but I figured that's just the company trying to sell product.
Thanks Race that's a great idea. I'll have to replace it since there's no spec for it in the FSM. I don't think the solenoid repair kit included that spring so it must be the original from 1981...probably a bit weak if anything.
Also something to consider is the locating pins on the primary cover, if they are missing or wallowed out you could try loosening
the bolts and holding up on it while tightening the bolts back down. And as above you could check the little springs on the pivot that pushes the Bendix out.
Thanks CRB that's a good thought I should double-check the primary cover alignment.
You guys got me wondering about the springs and it's prob them or the alignment causing the trouble. I ordered a new longer spring (#27 pic above) and I'll replace the smaller one too (#25 above) while I'm at it.
I installed a new shift lever (#13 pic below) and shift collar (#20 below) when I installed the new starter. The system turns freely by hand but there is some up/down slop in it, which I'm not sure is normal. There's no L/R slop just up and down.
Stock or after market outer? The alignment pin thing comes into play here. Lot of the after market outers the hole location isn't exact or pins gone. Some I've had to loosen the outer a bit and massage it around a rubber mallet while bumping the starter till they find its happy place.
Thanks TB yeah it is an aftermarket cover ... so if it is the cover alignment what is going on? Is the end of the jackshaft not sitting in the needle bearing the way it should?
If I leave it a bit loose, hit the START button and tap the cover with a rubber mallet ... is that the way to proceed? See if it turns over normally with a few taps?
Stock or after market outer? The alignment pin thing comes into play here. Lot of the after market outers the hole location isn't exact or pins gone. Some I've had to loosen the outer a bit and massage it around a rubber mallet while bumping the starter till they find its happy place.
A cryin Shame...But, The Chiwanese Parts business recently is Even Worse..
Thanks TB yeah it is an aftermarket cover ... so if it is the cover alignment what is going on? Is the end of the jackshaft not sitting in the needle bearing the way it should?
If I leave it a bit loose, hit the START button and tap the cover with a rubber mallet ... is that the way to proceed? See if it turns over normally with a few taps?
Look inside the cover it says Lifeline make a Frisbee out of it, pure trash.
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'81 FXWG Bendix hanging on Ring Gear
