Finnaly got around to replacing leaky seals in my inner primary. I'm damn sure I put the jack shaft assy back together correctly, as I have a FSM and doue checked it before I buttoned it all up.

Is there something I need to do to ensure that the outter primary cover is aligned so the shaft can enter the outter support hole in the primary cover?

When I hit the starter button, I can feel it trying to kick out through the primary. It doesn't spin though, just sounds like it wants to kick out real hard.

No issues prior to me fudging with it.

 

No special alignment but its real easy to get the jackshaft assembly ***-backwards...especially the coupling that has the circlip inside it.

 

If it worked before you fixed it then chances are whatever is wrong is something you did. (at least it is that way when I fix something)

 

I had all the components installed correctly, however, the shaft that moves through the inner primary was binding ever so slightly that the starter couldn't push through. I took the cover back off, took the gear that engages the clutch sprocket off and hit the button. She freed up and is running again.

 

same thing happened to me when i upgraded my jackshaft seal to the hard one to fix a leak on my 91 ....

gotta be very precise when reassembling everything... we live and learn with our evos!

 

Well, jumped on her this morn to ride into work. Click, no start. Y'all think the second relay will fix it up?

 

That or cleaning the plunger and contact points in the starter solenoid.

 

That's going to require the removal of the inner primary again isn't it?

 

If I can add the fused wire or second relay without removing the starter Itd be great, as I have already drained the primary twice in the last week and busted the seal on my new gasket. I really don't want to do that again. Thanks.

 

No..
You don't have to mess with the primary for either fix.

Read d1ggers thread for instructions for both.