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The journey continues... Well, I've now replaced all battery/starter cables with 2 gauge, new starter solenoid, and high torque starter I got from one of our members. In replacing the solenoid I discovered I was missing the spring between the solenoid and actuator (19) in the book. After replacing the starter, it seemed like the Bendix was bad as it didn't seem to want to engage the flywheel. When I removed the primary cover, I discovered the Thrust Washer (2) was missing. Where I'm at now is according to the shop manual I need to remove the solenoid shifter arm. To do that, the hex pug, marked (9)in the book, needs to be removed, pictures are attached. it's tight in there. It almost makes me wonder if the exhaust is aftermarket.
Does anyone know what size Allen wrench I need to remove the hex plug (9) in the diagram? After everything I've been through I don't want to use the wrong size and take the chance of rounding it out in there. I'd be screwed if I did that.
I'm trying to clean up the previous owners messes and it's frustrating. I'll be glad when I finally get there, but it's been hill after hill to climb. My local Harley dealer doesn't stock anything, so everything has to be ordered. I need to remove bolt circled in diagram. Does anyone know what size Allen wrench it takes? Its a tight fit with the exhaust in the way.
If you have the solenoid off, the arm(11) should have enough travel to pull the shaft (8) out so you can replace the bendix
i removed solenoid and starter both. The flywheel is in the way. Looks like I need to take the clutch basket out cuz it looks tight taking that bolt out of the top to release the shaft.
This bike has been a challenge but Ill stick with her.
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1988 FLHTC starter bendix replacement
