Just recently picked up a 96 Fatboy with the starter rebuilt, but in a box with other parts required for removal for the PO to get the starter out. Upon reassembly, I have found that the jackshaft bolt seems to be about 1mm too short. Without the interlocking washers on the jackshaft bolt, I can thread it into the jackshaft, but with the washers on it just will not bite. I looked at the assy and other diagrams to show the order of parts and everything seems in order. The only issue that looks a little funny, is that with the jackshaft bolt, splined shaft, and spring removed, the coupling can slide out of the hole until it hits the ring gear. I am wondering if anyone else has seen or heard of this issue and might lend me your experience...

 

Anyone???

 

Sounds like you have the splined shaft(spacer) reversed. It only goes
together one way. I'm talking of course about the link that connects
the jack shaft to the starter splined shaft.