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  #1 (permalink)  
Old 04-28-2016, 08:32 AM
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Rebuilding Starter

How hard is it to rebuild a starter? My starter finally gave out on me and was wondering if I should just have someone else rebuild it or attempt to do it myself. Any input would be really appreciated.
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Old 04-28-2016, 09:40 AM
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is it a Harley Starter or an Evo type?...... the evo ones are real easy and all parts are available in kits, just get ya manual out and read up on it and take ya time,
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Old 04-28-2016, 10:04 AM
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its on a 2003 Revtech 100
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Old 04-28-2016, 10:12 AM
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never touched a revtec but i guess they are the ordenary evo type, easy to build realy,.... give it a go, if no luck ya havent lost anything
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Old 04-28-2016, 12:33 PM
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You say it gave out, what is it doing , or not doing...? You should read this thread...Mr. Tuffass
has just gone through a complete troubleshooting ordeal with his,,, maybe you can find the problem here...

starter help
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Old 04-28-2016, 12:45 PM
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When I put the battery in and hooked up the grounds had sparks but didn't think anything of. Tried starting the bike and it started and the starter stayed engaged. shut bike of and it still was winding and the negative battery post got super hot. So I disconnected the wires and cables and hooked just the starter cables to the battery and jumperd the starter to crank and it didn't crank anymore if any of that makes sense I will be surprised LOl
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Old 04-28-2016, 03:30 PM
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Well, you are right, that doesn't sound very good does it? LOL..Why don't you just try to see if you can find out why your battery lead sparks when you hook it up? Something is on, or shorted some where. Why don't you just start by disconnecting your hot wires to the starter circuit...starting with the solenoid...if it still sparks then disconnect the starter hot wire and see if it still sparks..that would eliminate the starter..
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Old 04-29-2016, 06:17 AM
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I had to tap in the starter to get it to release from sticking and tried to jump it off a jumper box and my truck couldn't get it to engage I disconnected the whole wire harness and just had the positive and negative cables hooked up
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Old 06-01-2016, 08:02 AM
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had starter rebuilt and installed it back on the bike put the bike all back together when to start the bike and it just makes a knocking sound when trying to start it ugh and ideas what is could be?
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Old 06-01-2016, 11:47 AM
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Dang it.............have you checked the flywheel and clutch assembly? maybe something is loose and wobbling..
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Old 06-02-2016, 07:05 AM
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Checked everything and nothing is loose pulled the primary cover and turn the jack shaft and then tried to start it it engaged but then after a bit is stayed engaged and had to disconnect battery UGH so frustrating
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Old 06-02-2016, 10:49 AM
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Is it possible that the jackshaft is shooting out and hanging on the back side of the flywheel?
this would cause it to hang and maybe make a strange noise...but I don't even know if it is possible..is there away to look at it???............. You say you had the starter rebuilt....Maybe you have an issue with your starter relay hanging or starter button...my button did that.....! the spring broke in side.... a way to check this would be to just unplug the wire to the selenoid...run a hot wire straight from the battery and just touch it to the selenoid to crank it.....assuming that you crank the bike with a starter button..and relay...this will eliminate the relay or button , as a culprit..
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Old 06-02-2016, 11:09 AM
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Shovel I pulled the primary cover off of the bike and can see the jack shaft and but when the bike fires up the shaft satays engaged. I have a ignition switch on the bike like a car. I called the shop who rebuilt the starter and they don't know if the solenoid was replaced cause they sent it out to be fixed
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Old 06-02-2016, 02:51 PM
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It probably wouldn't be that ignition switch, but again it might...the only way to test it would be to do what i described above,....just run a temporary wire from the battery and touch to the solenoid....if the starter stays engaged when you let off....then it would be the solenoid sticking..and would eliminate the switch.....I can't think of anything else it would be, but that would be your first step..
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Old 06-02-2016, 03:34 PM
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when you hit the starter button, does the bike fire up or is the jack shaft engaging but not turning the motor over even though the starter is spinning ???
I ask this because IF it is doing this the starter clutch sounds like it is breaking down under loading.
the jackshaft wont return to the rest position unless the clutch basket is turning ,it needs the rotation to disengage.
however if it is spinning the motor and starting it is a sticking solinoid or there is power going into the solinoid LOW TENSION wire even after the starter button is released.
A photo or two of the starter may help id what starter you are using, I don't know what starters revtec use but early Harley EVO's used the Shovelhead type starter....
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