You didn't happen to take a side by side picture of the ok'd and new pinion gears did ya? Could you also provide the information on the replacement gear? My 77' does this exact thing but not all the time.
As it turns out, the first suggestions were the best. We wound up rebuilding the leads from the battery to the starter and it worked great. When the pinion comes out it is not perfectly aligned and depends on having enough battery strength to mesh the cuts on the pinion teeth with the ring gear.
Lots of guys on the IronheadSportsterGarage gave me grief for not having resolved that issue right at the jump.
Did you find the solution? It would be helpful to know for the rest of us. it's been over a year since you posted this.
I was thinking that even with the plugs out, it sounds like the starter motor itself is binding, either internally or externally through the gear. I've seen motors with just the slightest shaft play in the bushings and will cause them to draw mega amps and want to lock up even with no load on them. It's hard to tell this with all the gear noise, but it could be this.
Not an open primary. It is a Karata belt primary rather than chain primary. I just removed the the primary cover.
dougextra 1 month ago
HI THER'E I OWN A 1971 IRONHEAD SPORTSTER IN WHICH I'M IN THE MIDDLE OF REBUILDING IT, I WOULD LIKE TO NOW WHER'E YOU GOT THE OPEN BELT PRIMARY?
7279larry 1 month ago
Did you check the charge on the battery? A weak battery will cause the engine to not turn over more than 2 or 3 times.
tlococo99 5 months ago
You didn't happen to take a side by side picture of the ok'd and new pinion gears did ya? Could you also provide the information on the replacement gear? My 77' does this exact thing but not all the time.
bounceupinhere 9 months ago
I spoke withe the folks at Tech Cycles and they sent me a newer version of the pinion. Just a small difference but helped with the mesh of the teeth.
dougextra 9 months ago
I have the EXACT same problem with my 89sportster.
In addition to rebuilding the cables, did you do anything to align the pinion better?
Proctole 9 months ago
BeulahLips - Thanks for waking me up.
As it turns out, the first suggestions were the best. We wound up rebuilding the leads from the battery to the starter and it worked great. When the pinion comes out it is not perfectly aligned and depends on having enough battery strength to mesh the cuts on the pinion teeth with the ring gear.
Lots of guys on the IronheadSportsterGarage gave me grief for not having resolved that issue right at the jump.
dougextra 1 year ago
Did you find the solution? It would be helpful to know for the rest of us. it's been over a year since you posted this.
I was thinking that even with the plugs out, it sounds like the starter motor itself is binding, either internally or externally through the gear. I've seen motors with just the slightest shaft play in the bushings and will cause them to draw mega amps and want to lock up even with no load on them. It's hard to tell this with all the gear noise, but it could be this.
BeulahLips 1 year ago
The Trouble with Tractors
CrudeDude 1 year ago
starter weak?
shotgunwalter 1 year ago
Check the gear mesh to the ring gear on your clutch pack, it sounds like it is either to close or not meshing true, i had the same prob with mine.
sdime406 2 years ago