3rd week bike has been apart
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Cruiser
Joined: Feb 2009
Posts: 227
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3rd week bike has been apart
Its been 3 weeks now that I've been trying to figure out whats going on with my starter - jackshaft - inner primary issue. I'm at a total loss. I went to harley and wrote down all the part numbers and years of these 3 components on the bike as to what matches up for what year, ex. inner primary 90-93 or 89-93. Something isn't lining up right and I can't figure out what it is. Recap on the problem is the jackshaft is binding up in the oil seal when torqued to spec 7-9 ft lbs. I replaced the inner and outer bushings in the primary, the oil seal, new starter, 2 different jackshafts and three different jackshaft bolts.
I know what its not, I've tried 2 different starters, 2 different jackshafts, 2 different jackshaft to starter couplings, replaced oil seal, replaced inner bushing, 3 different jackshaft bolts. Its binding up with the outer primary off so I know the outer primary cover isn't the problem. I tried lining the transmission up to the engine, still same problem.
I've even removed the transmission from the bike and on the bench attached the inner primary and starter to it and I'm still binding up, when I say binding up I'm talking about when I torque the jackshaft bolt down and pull out on the jackshaft by hand its hard as hell to pull out and will hang and not go back in by itself. when the jackshaft bolt is only hand tight, everything is fine, if I somewhat shim the one side of the starter it seems to line up and is fine. It does this with 2 different starters, so I'm thinking its not the starter thats off. the only thing left is the transmission casing and the inner primary.
I'm going to try and get another inner primary tomorrow and see if that takes care of the problem, I'm thinking the jackshaft hole in the inner primary was made wrong from the factory, I've gotten shitty aftermarket chrome before where a hole is not centered and out of line. So we'll see.
I know what its not, I've tried 2 different starters, 2 different jackshafts, 2 different jackshaft to starter couplings, replaced oil seal, replaced inner bushing, 3 different jackshaft bolts. Its binding up with the outer primary off so I know the outer primary cover isn't the problem. I tried lining the transmission up to the engine, still same problem.
I've even removed the transmission from the bike and on the bench attached the inner primary and starter to it and I'm still binding up, when I say binding up I'm talking about when I torque the jackshaft bolt down and pull out on the jackshaft by hand its hard as hell to pull out and will hang and not go back in by itself. when the jackshaft bolt is only hand tight, everything is fine, if I somewhat shim the one side of the starter it seems to line up and is fine. It does this with 2 different starters, so I'm thinking its not the starter thats off. the only thing left is the transmission casing and the inner primary.
I'm going to try and get another inner primary tomorrow and see if that takes care of the problem, I'm thinking the jackshaft hole in the inner primary was made wrong from the factory, I've gotten shitty aftermarket chrome before where a hole is not centered and out of line. So we'll see.
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Cruiser
Joined: Feb 2009
Posts: 227
Likes: 1
Went out and bought a used inner primary, polished stamped HD, the other chrome inner wasn't stamped with anything, I'm sure some cheap aftermarket inner primary. Anyway, bolted it on to the transmission, torqued everything down and problem solved.
Makes me wonder if the bike was sold to me with the jackshaft bolt not torqued to specs so the jackshaft wouldn't bind up, because I know with that inner primary on the bike they must have had problems with it ever since they changed to the one that was on it.
Goes to show you that you get what you pay for, aftermarket chrome is inexpensive for a reason, its not that good of quality. Hell, I've bought hand levers that I had to drill the hole a little bigger just to fit the pin down through to hold them on the switch housings.
Makes me wonder if the bike was sold to me with the jackshaft bolt not torqued to specs so the jackshaft wouldn't bind up, because I know with that inner primary on the bike they must have had problems with it ever since they changed to the one that was on it.
Goes to show you that you get what you pay for, aftermarket chrome is inexpensive for a reason, its not that good of quality. Hell, I've bought hand levers that I had to drill the hole a little bigger just to fit the pin down through to hold them on the switch housings.
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