I am going for the contact. That is about a $15.00 repair kit part for the contact and copper tabs. Not sure how you could tear or break the pins and springs on the ramps inside Harley starter gear. Plus you do not need to put starter to check there first. Unless you were real good with the dremel it will come back and you may need to install kit. But glad you go it fixed.

 

Good point. If the problem returns that will be my 1st kick at taking care of it. Thank you for the observation. You have a valid point. Time will tell, if it does reoccur I will update this post for everyone.

 

wire diagram Harley starter . switch on handle bars and start relay on fuse box are not shown and are in the wire going to contact switch in solenoid

https://www.hdforums.com/forum/gener...n-starter.html

Actually since this is about the third post on here about your condition. I'm on vacation with no Harley to tinker with or ride and plenty of pondering time.

I was wrong in my statement that the starter contact in the solenoid was what drove and held it in. It in fact is the starter relay that provides the power to drive and hold the plunger in. On its way it closes the contact for the starter motor which spins up the starter pinion just as it is about to contact the big ring gear on the clutch drum and thru the primary chain turn motor over. If you have a big vice why don't you press starter clutch apart and look and see what the pins and ramp look like. There is a lot of grease in it. It could just be all dried up and was jamming it. Harley's system uses pins. Is the all ball unit use ***** or is that just a term they use? Did you replace electric motor?

 

No I did not replace the motor. Only the starter clutch and cleaned the contacts in the solenoid.