Starter Clutch Wrong Size

  • Dusty54
    Dusty54
    18 days ago
    Bike: 1991 FLSTC Heritage Softail
    ISSUE: Rebuilding starter motor. Standard motor has 1/4in x 5 1/2in jackshaft bolt with a 1/4in thread,  that screws into the starter clutch shaft. 
    REPLACEMENT: Replaced starter clutch and shaft with genuine Harley replacement kit which includes the clutch and shaft (Harley p/n 3151694A) - Harley parts dealer assures me this is the correct part.
    PROBLEM: Issue is the original clutch starter shaft is for a 1/4in thread jackshaft bolt. Harley parts replaced the shaft with a 3/16in jackshaft thread. There is no such thing in Harley Parts for a new 1/4in x 5 1/12 in jackshaft bolt with a 3/16 thread. My Harley Parts dealer is incommunicado concerning this issue. Anyone got any ideas? (Have tried machinists in my area but interest in making a blot to suit is zilch!
  • perthhog
    perthhog
    18 days ago
    Buy a aftermarket Jackshaft kit like ultima / Midwest  they come sometimes with the two 
    Different size bolts  that’s what I did   It’s due to the earlier style 89 to 93 starter than 
    The 93 up style Nippon denso starter

  • Dusty54
    Dusty54
    18 days ago
    Thanks. I purchased an All Balls jackshaft but it has an issue of lifting up when engaging the 'fly wheel' teeth and grinds the top of those teeth. I tried it four times and found each time the jackshaft bolt came loose. After the 4th try the jackshaft bolt broke at the transition point leaving the thread inside the starter clutch shaft. Great. So I want to return to the original jackshaft but cannot because of the bolt thread size, that the fact my harley parts dealer claims I have the correct starter clutch kit for my bike, even though I explained correct shaft is 1/4 inch thread and he send me a 3/16 threaded clutch shaft. The p/n for my jackshaft bolt is 4325
    so if you go to this web site: https://www.scribd.com/document/521939581/Harley-Davidson-Hardware-Listing. This web site lists every bolt, nut and washer Harley have every used and it shows the p/n 4325 is listed as a 1/4inch X 5 1/2inch bolt. Yet my dealer cannot understand that!
    x
  • perthhog
    perthhog
    18 days ago
    Not sure why the bolt comes loose  it normally has a locking washer on it ? 
    As for it lifting up  is the Bearing bush in the outer primary cover worn ? 
  • Dusty54
    Dusty54
    11 days ago
    Thanks. Every thing is brand new - jackshaft - starter clutch and clutch shaft.  Gone back the original jackshaft. Will not buy All Balls jackshaft or similar, again.