Pulled everything in the starting system mechanical. First the solenoid and found the rubber boot was busted where it seals to the primary housing, thus sol. was in too far. Then I pulled the starter all ok there. Rolled the starter/jackshaft gear all ok there. Pulled clutch basket (ring gear eat up) and then the jackshaft/starter clutch. Took all components off shaft and the spacer noticed spacer would not allow the clutch to move much. So I took spacer to HD shop in Danville and had Mech. look it over (along with jackshaft) he measured the spacer (looked homemade was made from copper tubing?) and it was 13/16" the OEM one in the book is 7/16" so the starter clutch could not return when engine started and solenoid disengaged and eat the ring gear up. Now I have ordered a rubber boot and spacer. and will put it back together. The PO must have done some work and lost the spacer and just cut a piece using the guesstamation technique and run it like that.

 

Good to hear that you're on your way to a GOOD repair.

 

Would have never thought to check the spacer. Just lucky I saw that it was copper, everything else is steel. Otherwise I would have put it all together and ruined another new set of parts.

 

If he was gonna rig up something it looks like he would have at least used metal. Not a smart move.

 

Just keep in mind from now on that the PO wasn't a good wrench. Anything else that might come up check it 110%.

 

Good catch, things like that are impossible to diagnose over the internet!! I think i'd put that copper ring on my key chain as a "momento".