Starter pinion not always engaging into ring gear
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Intermediate
Joined: Dec 2020
Posts: 28
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From: FL
Starter pinion not always engaging into ring gear
Hi working on my 1995 FLHTC. Had to replace both my ring gear and pinion they were chewed up from not engaging properly. I changed the jackshaft thinking it was the issue so converted it from the 3 piece oem to a AllBalls one piece shaft the issue is not fixed sometimes it engage sometimes it won't don't want to chew up the new gears. I think what's happening is the pinion is spinning to fast when it hits the ring gear I read somewhere that I should shim the jsckshaft out to correct the issue. Anyone have any thoughts on this and if swimming is needed are there specific shims that should be used. Thanks ahead of time for any ideas or suggestions on where to buy the necessary shims.
Outstanding HDF Member
Joined: Dec 2008
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From: Ohio
The pinion should only turn slightly until it is fully engaged with the ring gear. It sounds like maybe a problem in the solenoid turns on the starter motor too soon. Have you disassembled it and checked it out?
Road Warrior
Joined: Nov 2007
Posts: 1,800
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From: Houston, Texas
I too think it's a solenoid issue not fully extending the the pinion into the ring gear. Here's an interesting video on things that can go wrong with a starter. Either the solenoid is either weak or hanging up and not fully extending before engaging the starter motor.
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Intermediate
Joined: Dec 2020
Posts: 28
Likes: 4
From: FL
Going absolutely crazy over this I have checked everything from a to z replaced starter new wires you name it all the common issues you can have and still the starter won't fully engage it does engage sometimes. I concede this is passing me of to no end. Totally stock motor absolutely no modifications have been done. There has got to be something I'm missing obviously if anyone has any ideas please tell me. 95 FLHTC
Outstanding HDF Member
Joined: Dec 2008
Posts: 2,007
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From: Ohio
Some possible causes are:
1) the solenoid plunger makes early contact turning on the starter motor before the pinion is fully engaged with the ring gear.
usually caused by crud/corrosion on the plunger.
2) the ring gear not seated properly. Has it ever been removed? Replaced?
3) the starter assembly attachment is misaligned or not fully seated to the inner primary.
1) the solenoid plunger makes early contact turning on the starter motor before the pinion is fully engaged with the ring gear.
usually caused by crud/corrosion on the plunger.
2) the ring gear not seated properly. Has it ever been removed? Replaced?
3) the starter assembly attachment is misaligned or not fully seated to the inner primary.
Thread Starter
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Intermediate
Joined: Dec 2020
Posts: 28
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From: FL
Same issue with two different starter assemblies pretty much rules out number 1
I did replace the ring gear because of the problem it had chewed up the original replacing it helped because the teeth aren't all damaged but the original issue of not engaging properly which is why the original fly wheel was damaged is still there.
The original starter was never removed before this started happening at this point I have had the new one out several time checking for issues . It is flush mounted to the inner primary far as aliegnment to the best of my knowledge after talking to several HD mechanics there isn't any real aleigning to do everything pretty much bolts into place and the issue existed before the original starter was removed. If you know more about aligning than what I have been told please enlighten me. Now I'm noticing it possibly has to do with the power so lately I've been looking into a grounding issue or more accurately if it's a grounding issue. I've been riding for 60 years now started when I was 10 and just had a birthday that makes right at 60 years I've been wreching on HD for about 45 years and built a couple of them I'm no professional but I do have a little experience but this has got me by the *** I admit.
I did replace the ring gear because of the problem it had chewed up the original replacing it helped because the teeth aren't all damaged but the original issue of not engaging properly which is why the original fly wheel was damaged is still there.
The original starter was never removed before this started happening at this point I have had the new one out several time checking for issues . It is flush mounted to the inner primary far as aliegnment to the best of my knowledge after talking to several HD mechanics there isn't any real aleigning to do everything pretty much bolts into place and the issue existed before the original starter was removed. If you know more about aligning than what I have been told please enlighten me. Now I'm noticing it possibly has to do with the power so lately I've been looking into a grounding issue or more accurately if it's a grounding issue. I've been riding for 60 years now started when I was 10 and just had a birthday that makes right at 60 years I've been wreching on HD for about 45 years and built a couple of them I'm no professional but I do have a little experience but this has got me by the *** I admit.
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Road Warrior
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