I have a custom build, but basically it's an EVO era Softail. S&S V-96, Baker DD6 Tranny, BDL Belt Drive, Protorque starter, and 1pc AllBalls Jackshaft. I used OEM part numbers ordering parts.
The starter "whirls" when engaged which gave me the notion that the solenoid wasn't kicking out the Jackshaft. I returned the starter which checked out OK, but they sent me a new one anyway....same issues.
Everything bolted up, no problems there. I pulled the outer primary, manually pulled the Jackshaft into the starter gear but see no issues there. I can't see any "wear" where the jackshaft engages the starter gear. I'd like to try rolling the engine, but am leery of trying it with the jackshaft un-supported.
It's obvious there's an alignment issue. Only thought comes to me, is that there was a starter change between '92/"94. I have a '94 version.
This doesn't happen all the time, say 1/2 and 1/2.but it has me baffled

 

The starter motor will not get power until the solenoid plunger moves fully toward the left, at that point the contacts come together.

The pinion gear is on the other end of this plunger shaft, so you see that until the gears are engaged, the motor will not spin.

If the starter motor spins, but the engine does not, the starter clutch is probably bad.

I bet they sent you the same starter, but never checked the starter clutch...

 

No,it's a new starter.... I made a mark on the returned one. I trust the Protorque folks. As I said, it's an intermittent problem. I think it's an alignment issue. I just read an old post where as the tech said that most problems described as mine were the cause of a slight misalignment in the outer primary cover, his solution being to loosen the outer primary bolts, use a 2x4 and pry the bottom under the derby cover while tightening the bolts.
will removing the outer primary, spark plugs and rolling the engine over damage the jackshaft or other starter components, as the Jackshaft will be unsupported? If I can test the unit this way and have no engagement issues then it'd add credence that I've got an alignment problem in the outer primary.
I was a toolmaker and have cut every form of gear imaginable....Doesn't take much misalignment for gears not to engage or mesh properly. Thanks

 

Disconnect the positive cable (don`t let it touch the frame, wrap it in a rag).

Disconnect the small wire on the start solenoid.

Use a small jumper wire, jump from the positive battery to the small connector on the start solenoid.

This will energize the solenoid, but you won`t have power to the starter motor (remember, disconnect the positive cable from battery first).