Sorry about the photo. Tilt ur head to the left!!

Ive got the starter out ready for the clutch kit. The bearing that supports the throw out gear in the primary case seems to have a lot of play. Any idea what the norm should be??

In the primary case, above the clutch pack

Sorry wrong photo

My phones playin games with me. That is the right photo, just on its side again. When the starter was still bolted in that shaft with the cog on it would easily move 2-3mm side to side. Not sure if thats right it just seemed excessive to me, and the front edge of the teeth look worn. What do u think?? And there was some metal filings on the plug when i drained the primary, it was clean last time i changed it!

Just been reading the manual, I think its the jackshaft bearing

Ok cool. Thanks!

Ok so the starter is back in and i just gave it a test before everything else is back together. Hit the button it threw the cog out once but it didnt retract. I had to push it in by hand and then tried again and it just clicked. I used my little jump starter thing and the battery may be a bit low. That explains the tick but shouldnt it retract automatically, power or not?

I'm not liking the sound of this Matt, sorry I haven't been on here for awhile so just catching up.

As you have done several things since you began this it may be difficult to work out what is going on but I honestly think the problem was with the PC111 wires being removed. I'm correct in saying the bike started okay before you removed the wires?

Have you now removed the PC111 from your bike?

How on earth did a dealership put a SERT onto a bike with a PC connected without noticing it was there????? I have my doubts as to the SERT codes were ever working as the SERT isn't a piggyback system like the PC111 is so I wouldn't be surprised that once the SERT is removed that the PC111 takes over again.

The connector you were trying to use for the o2 sensors was from the PC111 (I assume you now know that) once the PC111 is removed and the bikes ECM connector is put back in place then you should have not problems wiring into the ECM for the o2 sensors. This "should" fix the non starting if this was the issue.

Keep us informed mate, I'll keep an eye on this thread until we hear good news.

CH

Ok so the PC3 is out and the original harness is straight into the ecm. It all made so much sense when pc3 came out, no pins in all the right places. So now the O2s are wired in, so much easier this time. Its actually SEPST not SERT, if that makes a difference? I dont know how the 'experts' got it so wrong either. Being my first harley I didnt know what the wiring should look like, but it looks a lot simpler now! I talked to a different dealer about the way it was starting -slowly getting weaker til the point it would just spin with out turning the engine. I thought it wasnt engaging but maybe it was and the starter clutch was stuffed. So I put the new starter clutch in today and the starter definately engages but still wont budge the engine and now wont retract. My battery is on charge, I think I need to wait til its 100% before trying again

Hi there Oz Nightrain, I cant give you any advice. I'm just keeping an eye on this thread, You seem to be in a world of hurt !!!! Just giving you moral support . I'm rooting for you from cyber space . Don't give in , we all want to see your bike going. !!! Good Luck,

Thanks mate. But i tell ya im gettin very close to just chuckin it on a trailer and takin it to a shop and say just make it work!!

No blame on your part at all Matt, how were you to know but a dealer really should be looking at the bike.

SERT or SEPTS doesn't matter as both are done by a HD dealer and without the software you can't do anything with the dongle that you get. The issue I have is that if the dealer checked what software they put onto your bike then surely they would have noticed something was up. I believe that the PC111 would have been running the show and the SEPTS was doing nothing, now that you have removed the PC111 you will need to confirm that the SEPTS software is in the ECM otherwise you will be running lean as.

Fingers crossed that it turns over and fires up.

Tried a starter test with a full battery, still sticks out. Must be solenoid or relay, right??

Are you trying the starter with the primary cover off ?
If so, not a good idea, as the outer cover has a guide bush that the pinion runs in.

Yes I was. I thought as long as the engine didnt start it was ok. Didnt realise there was a guide, thanks for that!!

Yep u were spot on Hilly. I just stupidly took the dealers word for it that they actually new what they were talking about!! So hopefully ill get a solenoid for the starter 2moro, give some fresh oil and a reflash and then i can start doing some data runs! Thanks again!!

The PC is an interceptor, it makes no changes to the Ecu.
It only alters some inputs, and changes injector pulse width.

I did usually enjoy Scotty's posts.

A massive thanks to everyone involved in helping me get the old girl running again. She fired up first go, no problems. Starts and idles well, no more misfiring/hesitating, no more codes, bulk power and back to her former glory. So thanks again everyone, ive learnt so much about my bike and cant beleive the amount of people willing to help out. Cheers, Matt. 

Good news Matt, I can almost see the smile lol.

Speedzter, I think we may have been saying the same thing but with different terminology, if we had of been talking face to face I'm sure we would have realised this rather than how things can be interpreted on a forum.