I just replaced the mainshaft and jackshaft seals on 03 FLHT. Put the thing together now the starter does not spin. I hear what sounds like 2 clicks and that is it!! Please help, did I put something together worng? Thanks

 

Double check your connections...

Especially the ground strap on the starter, but check them all. Even at the battery.

 

I checked all the connections, all good. Found the starter relay fried. Replaced the relay, tried to start and the relay fried again!!!!

 

Sounds like you may have pinched a wire . I think it would take a dead short to ground to fry the relay.

 

Check the cables at the starter again...

I agree that it seems there has to be a dead short some where. Did you have any probs with the starter before you disassembled the primary? If not, then it has to be something you removed and replaced.

Look closely to be sure there aren't any chaffed wires, or broken insulators at the two wire connector on the side of the solenoid, and the cable going from the solenoid to the starter motor on the other side for broken 'boot' insulator and possible short there.

 

That suggests the wiring is not connected correctly or there is a dead short. Check again!

 

I am going to offer a scientific wild *** guess(SWAG). The electricity leaves the starter relay and goes directly to ground, thus there is no resistance to limit the amp draw. One other guess is that the polarity is wrong, but I don't see how this could happen unless the battery was improperly installed.

 

I had thought about asking him to verify that he didn't put the ground cable on the starter, and positive on ground. Figured it would blow the battery that way though, or at very least let him know by throwing sparks as soon as he tried...

 

After looking closer, I am not sure if the starting relay is frying or the "key starter relay" is frying. I just ordered more relays so I will have to wait to find out. In the mean time, I have found the manual wiring drawings are wrong. It seems that the key starter relay is not used on the '03 FLHT so until I get the new relays I won't know if it might have always been blown (it is actually a short accross the coil, I think it is the diode). I am also going to take the dam thing apart and check the stack of the starter/jackshaft. I don't think the jackshaft is moving fully to the left. Thanks for the posts!!

 

Yeh, those would both be known as 'a dead short'...