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Have a 2002 Road King Classic FLHRCI. Twin Cam 95" is the only mod to the engine.
Having starter problems so I took it off the bike and repaired it using the HD Starter Solenoid Rebuild Kit.
Everything went fine until I tried to reinstall the starter into the bike. The starter itself went in without a problem.
BUT
I can not get the starter to mate properly in that the pinion gear sits flush with the case and will not retract enough so that I can install the jack staff.
three pictures shows the problem with no power at all.
Item 45 in the parts catalog is flush with the inner primary cover and will not recede any further.
I suspect the coupling (item 30) did not mate properly with the starter shaft extension but am at a loss as to how to get the things lined up.
When I removed the starter form the bike the coupling (item 30) came out with it and was just loose on the shaft which is where I put it when reinstalling.
Picture 3 shown the pinion gear in as far as it will go. Not enough to install the jack staff.
Am at a loss as to how to remedy this situation and will welcome any and all suggestions.
I apologize for adding the images inline. I could not figure out how to add them as an attachment, The New Thread creation routine did not give me the option to add as an attachment.
I followed the HD service manual to the letter Except I had to remove the exhaust to remove the oil filler spout. Other than that the manual went smooth.
HELP.
Last edited by Rustyg500; Sep 9, 2022 at 04:13 PM.
I havn't rebuit that year, but the ones on 6 speeds, I had to ***** in. Luckily I thought to check before I installed. It was buried in grease, if I remember.
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Starter problem with 2002 Road King
