starting problems

[IrishGuy]

guys- I got the karata installed and it looks good, sounds great, and rides like no other. I'm really pleased. More on that later... Only problem is the bike is progressively harder to start (now it doesn't seem to have enough juice to turn the engine over). I just put it on the charger and will see if that helps.

Is the alternator that disk that's right off the engine shaft? I have a clankety noise coming from that area :bang: If so my bike probably isn't charging while I ride. Does that sound right? If so any idea how much $$$ a new one will set me back?

two steps forward one step back I guess

 

[Thumper169]

Is everything tight? Shouldnt be making any noise at all down their, I would guess if it's clanking then something is loose, might have cratered the stator but no noise should be heard. Go to the how to section as checking the stator output was just done, May just be a shitty battery as well.

 

[alhall88]

The large disk is considered the rotor or some call it a flywheel. Was there a shim in front of the rotor? If so did you put it back on and also did the front of the front pulley and the front of the clutch basket line up within .015 within parallel? Just a few things I can think of off hand.

 

[Moespeeds]

Make sure your front pulley nut is tight. Grab your front pulley and push/pull on it. If there is any lateral play at all you have a problem. If it is loose, chances are you sheared all the teeth off your rotor, and it's just spinning free. BTW, you may not have lateral play but could still have a loose nut. If you keep riding like that, eventually the timkin on the crank will back out, and that will cause lateral slop. You should have a thin washer on the inside of your rotor, and a big fat one (almost 1/4") on the outside of it. Rotor should be tight without the slightest bit of wobble.

 

[IrishGuy]

Yeah everything was tight and I didn't see any lateral play. I took the washer off that was in between the flywheel and the sprocket of the enclosed setup. I replaced it with the big spacer that came with the karata. The instructions made no mention of using the old washer WITH the spacer.

So what you guys are saying is that it should go like this-> flywheel, little washer, spacer, pulley, tranny nut?

 

[Moespeeds]

No, it should be crank seal, thin washer, stator (flywheel), fat washer, pulley.

How do you know the pulley nut is tight, did you look at it? If you push on the stator, is there any play at all in it?

 

[IrishGuy]

ok gotchya, thanks. i didn't take off the flywheel so the thin washer would still be there. forgot to mention- yes, everything was parallel. I'm still baffled. I will dig into it more tomorrow.

thanks again guys

 

[Moespeeds]

If the pulley nut comes loose, you will hear the stator wobbling like sliding a bowl across the floor upside down. Ask me how I know. After my 3rd stator I safety wired my pulley nut so it can't come loose.

 

[Staffy]

IrishGuy BREATH....it could just be a coincidence...how old is your battery and would you say it was time to replace it? Do you have any way of testing the battery?

Now on to the Primary itself - I have done this install a couple of times. It is COMMON to hear a tinkle from the rotor woth the engine nut OFF/loose. Once you tighten it the sound should go away. (As a habit I always pull the rotor off, use some eletrical clean and rinse the area/rotor before bolting on the pulley).
I some how cannot recall the small washer inside the rotor housing, if I remember correctly it is just an oil seal, which could have the washer that Moe is referring to - I have not paid attention to that. Else the order is correct, after the rotor, use the KARATA spacer then the pulley and finally the nut.
(I do something different and that is just to satisfy my setup....After the rotor, use the KARATA spacer, then the pulley, then the ORIGINAL washer/spacer and then finally the engine nut. By doing this I push the engine nut out by about a 1/4 inch making it easier to grip onto in the event I need to remove it at a later date. If you look at the inside of the pulley it gets difficult to grab the engine nut unless you have a real thin-walled socket. Adding the ORIGINAL spacer here helps - in my opinion.
Next if it is the starter that is causing you some grief, I would check the 2 starter bolts which you replaced during the setup. These are difficult to get to and it could very well be possible that you do not tighten these properly along with the starter/power cable. (please check it)
I don't believe you could have done any damage when installing the primary. The installation is pretty straight forward and if you didn't pull the rotor to clean it in all likely hood it is either the starter bolt/connections or the battery. Do not start opening it up before checking these.
Another side note, just in case you run into it as I did, you may find some oil leaking near the tranny. I was concerned and thought I had busted my tranny oil seal - opened the entire primary only to find that it was the residue oil coming out of the starter which is a result of the wet primary and should not have you worried.
Good luck and keep us posted. Here to help.
Thanks - Staffy

 

[Staffy]

Yes to Moe's point, how did you tighten the engine nut - with red and an impact gun I hope?

 

[IrishGuy]

You're right, I always forget to try the easy stuff first :roll:

1. I still have the same 'ol stock battery in. I will get a new one in the morning. Does harley have a battery that'll work in the dog? If so which one should I get, and does it do 330cca? I think I read on here that they do but I'm not finding it in the search.

2. I will double check the starter bolts first thing in the morning.

3. I checked and the nut wasn't budging. and yes I used an impact wrench and red loctite. Maybe I still didn't get it in tight enough though? I'm not sure how to dial it in exactly 125 - 150 ft/lbs as mentioned in the instructions. I'm worried if I put it in too tight I'll break the bolt. How are you guys doing this accurately?

 

[karata]

shaft:

You're right, I always forget to try the easy stuff first :roll:

1. I still have the same 'ol stock battery in. I will get a new one in the morning. Does harley have a battery that'll work in the dog? If so which one should I get, and does it do 330cca? I think I read on here that they do but I'm not finding it in the search.

2. I will double check the starter bolts first thing in the morning.

3. I checked and the nut wasn't budging. and yes I used an impact wrench and red loctite. Maybe I still didn't get it in tight enough though? I'm not sure how to dial it in exactly 125 - 150 ft/lbs as mentioned in the instructions. I'm worried if I put it in too tight I'll break the bolt. How are you guys doing this accurately?

Do not worry about breaking the (bolt) shaft just follow my instructions and when you need help just give me a call.
Jim@karata

 

[Gas Man]

Irish... a HD AGM battery for any year softtail will work!!!

 

[Staffy]

Do not worry about breaking the (bolt) shaft just follow my instructions and when you need help just give me a call.
Jim@karata

YUP...what he said - I live and breath through Jim's advise. He is one of the BEST and I have all the respect in the world for him. And he's not kidding either - just follow his instructions and all will be good.