long story short, my starter solenoid only engages the gears about 20% of the time. Took primary cover off and held shaft in by board and had wife crank about 12 times. 80% of time the solenoid doesnt pull in enough to engage gears, only 20% of time do the gears engage. I have a new relay, new starter solenoid, new boot, new spring, new starter pushbutton, new on/off switch and new wiring harness. It "clicks" every time, but just whirls and doesnt engage most time. Looking at all the diagrams I have its put together properly. Also, I can turn ignition off and push on lever (solenoid end) and it seems to move freely and engage gears each time I do it. Doesnt seem to be binding as far as the lever is concerned. Any ideas? Thanks.

 

Battery, battery cables, or connections??? Ground cable???

 

check to see if starter jack shaft is bent

 

Thanks guys. I have a new battery with #2 welding cable and hypress connections and alls tight. I'll pull the unit again and check the shaft, although it meshes good when pushing it by hand.

 

Ok. After replacing some starter parts and installing some that wasnt there before, the starter is now fully engaging but acts like it just aint got enough "umph" to turn the motor over. Battery fully charged (had it on charger last night-12.8 volts) Could it be the starter drive, or could the starter motor be going bad. Hooked battery to motor while it was out and it spins but not sure how much torque or "umph" it has. Any thoughts?

 

Probably the battery. I had a brand new Walmart battery (240 cold cranking amps) fully charged, while jumped from my truck, and on the charger still, and still didn't have enough to turn my 86 Evo over. Bought a HD battery, and works every time.

[EDIT] Checked the voltage on the Walmart battery before starting, I was getting 12.9+

 

I have a spare car battery. Use it working on car and also put it in bronco when I want to drive it. I'll set it next to bike so positive leads will reach and jump from negative to bike frame and see if that helps. Thanks

 

Ok, put broncobattery on bike (450cca)withbronco running. Had 14.4 volts at bike but still would not start. Engages but them acts like its slipping. Jack shafts appears straight just by looking at it and starter drive slides easy and ehgages good it appears. Ordered new starter drive in case the internal parts that allow it to slip if it stays engaged might be going south allowing it to slip while trying to start.