I have a late 93 FXSTC,  bought and installed a 1.4 ultima thunder fire starter on original jackshaft and it seems that the 3/16 jackshaft bolt is to short.  The kit comes complete with a 1/4 inch bolt and a 3/16 inch bolt with the end of the starter drilled and taped to take both sizes. The one used in my case is the 3/16 inch bolt (the 1/4 inch wont go through the jackshaft) allthough longer than the standard HD bolt is still to short by about 15mm.

Do i need to purchase a Ultima jackshaft assembly ( maybe a shorter one) when using this starter motor or am i doing something wrong??? I have spent countless hours trying everything i can think of to get it to work and am almost at the point where the HD factory one can go back in!

Please help!!!

 hi there i have a ultima starter and a oem  jackshaft assemberly  in the shed i wil dig it out in the morning and see if it al fits and let you know,,i just thought of somthing did you have the sleave with the internal spline c clip facing the right way it has a counterbore on one end and go s on in one direction but can fit  both ways ,cant remeber which way though, will look in the morning,

Hi perthhog i tried it with the sleeve in both ways , still no luck. The counterbore from the best of my knowledge should be fitted to the inner primary side and not the starter motor side. Thanks for your help it will be interesting to see what result you get. The bolt length i have is 6 inch

hi there 93 softy  the one i am talking about is the the on on the starter side between the starter output shaft and inner primary about the size of  AA  battery not    the prmary side spline sleeve which sits inside the inner primary.but wil stil have a look for you tommrow,

You would think that the difference in bolt length would be equivalent to the extra depth of the 3/16 thread in the bore of the end of the starter motor output shaft.
As in, distance from the end(to allow for the 1/4 thread first)
Have you checked this?
If the 1/4 thread is an inch long, for example, the new 3/16 bolt is likely to be an inch longer than the stock one.
If all that tallied up, then you might conclude that the issue was elsewhere.

Did the jackshaft assembly fall apart?
Do you have the collar(the one that runs in the inner pri housing bushing) the right way in that assembly?

It should be flush.

hi there softy93 , i had a look for you   and as i was saying lastnight the spacer/coupling is around the the wrong way (same as dynarider was saying  issue elsewear) the counterbore end  faces the primary side cover not the starter side .hope this helps

Thanks for all the help lads, perthhog if i can ever get out of work today ill check out the coupling, however i have tried this installed in both directions, but it was getting late and was extremely tired and pissed off that it wouldnt fit lol. ill try it again with a fresh mind.

Thanks again, ill post my results tonight.

no worries 93softy if i can help any more i will just ask .pain in the arse doing a starter ,did your ultima come with the push button end cap ? if it didnt get one saved my arse  more than once,

ok had another go at it today, all installed as per manual, bolt is still to short. If i install the coupling facing the starter ( the wrong way) and leave the lock washer off i can get the bolt to thread on but im sure the lock washer MUST be installed. ARRGH.

Can the jack shaft be cut say 5mm??? if so it would all work.
i have some ics to post once i work out how to do it.

Pics are here

http://i945.photobucket.com/albums/ad291/93softy/26092010360.jpg
http://i945.photobucket.com/albums/ad291/93softy/26092010359.jpg
http://i945.photobucket.com/albums/ad291/93softy/26092010361.jpg
http://i945.photobucket.com/albums/ad291/93softy/26092010358.jpg

hi there 93softy i had a look at your photos and i thinks somthing is going on ., in your pic 3  where u can see the belt and jackshaft i dont think you should be able to see the spline between the coupling and the main jackshaft  shaft  i will go and have looksee  at mine  and the spare  bits i have  and see if i can figer it

 buy the way dont cut it because it extends to your outer  primary cover  with the bush in it ,may cause other problems.

hi there ,by your pics it looks a if everthing is to far left  normally you have to push the pinion gear the won that engagages the ringgear back a bit , when you are doing the bolt up ,but your main shaft is sticking past that  plus the gap u have between the starter cupling and jackshft i think your problam is in the primary side maybe ??? that frame color looks great though.

Success!! i put it all back together bolt to short same old story then the light came on, what if i hook up the battery direct to the soleniod to throw the shaft out on the starter and maybe i might be able to get the bolt in. It worked. All bolted up, tested and it works!
perthhog the pinion gear was pushed back and resting against the ring gear maybe thats why it looked odd in the pic as for the spline being visible at the coupling, i thought was odd to but now that it is all bolted up after engaging the soleniod it is no longer visible. one hurdle over bring on the next.

not sure what the name of the colour is, just picked it from a colour chip that my painter had, i do have the code though. I have done a full ground up rebuild flushed all the welds on the frame , paint , engine rebuild, billet front end, stacks and stacks of chrome etc etc. ill be glad to be finished, almost there but the final touchs always seem to take the longest!!

Once again guys especially perthhog for taking the time to check the bits you have in the shed, cheers for all the tips and advice been a great help!

top stuff love a happy ending, i did the rebuild thing to my girl 2 years ago,and it dont stop never does as soon as work out this photobucket thing i will show pics,hope we see yours to,cheers

Glad you got it sorted Softy and a big thumbs up to Perthdog,just reading through this it seems like you went above and beyond the call of duty..

Now that it is all together and working, you should NOT (as mentioned) be able to see any of the splines as you can in the picture.
If the jackshaft is still in the same relative position to the ring gear, I am of the opinion that the COLLAR (not the coupler) is in backwards, or not fitted correctly in some way.
The jackshaft is definitely in the wrong position in the pics.

DynaRider, your comments got the better of me as i thought this was one i had beat. Check out the new pics of the completed installation, let me know what you think.

http://i945.photobucket.com/albums/ad291/93softy/27092010365.jpg
http://i945.photobucket.com/albums/ad291/93softy/27092010363.jpg
http://i945.photobucket.com/albums/ad291/93softy/27092010362.jpg

"Now that it is all together and working, you should NOT (as mentioned) be able to see any of the splines as you can in the picture. "

And......... you cannot see any now. So no need to pay any attention to the part after the "IF".
Looks good.