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Just finished the starter refresh per Mr. Magic's tutorial. Now I'm having a helluva time getting the starter back in. For some reason I cannot get the splined end of the starter shaft to match up with the gear inside the housing.



I'm so mad at myself right now I can't stand it. I know there's an easy way to do this but I can't figure it out. I've been tussling with this thing for at least an hour trying to get it back in!
 

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I had a similar issue with my 1100. I somehow munched up the shaft spline. I took the gear out of the housing and cleaned it up. I found the spot where it would slip on.I lined up the sweet spot, and put it all back together. I had to slightly turn the shaft ,with my fingers then tried it several times until it matched up.I know it makes you nutz when the installation is the longest part of the job.,,
 

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just wondering, is the bike on the center stand or the side stand?. i have had my starter out about 3 times while on the center stand and had no problems to put it back in. some people thinks is easier on the side stand, the gear by gravity is centered on the starter hole while on the center stand.
 

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Thanks GW... I'll try that tomorrow. Too mad at myself to try it this evening.



William.... I pulled the starter while the bike was on the center stand and tried over and over again to get it back on while on the center stand. Just to see, I put her on the side stand and tried. No luck.



I'll put her back on the center stand in the morning and try the WD-40 GW suggested.
 

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yep theres a chain that the inner sprocket set in. i had a little problem with mine. but sat back took a couple deep breaths and it slipped in finally. i did have mine on the center stand had to line it up and after about 30 mins and a lost inner gear that i was able to fish back out. i did take the inner gear out and deburred it cleaned it up and that's when i got it. i think i burred it up after 30 mins of trying to get the starter to line up. it didn't take much to keep it from going in.
 

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OK.... pulled the gear out of the housing and tried to fit it to the splined shaft on the starter..... no go.... So I recleaned both.... steel wool to remove any burrs that may have been there.... still no go.



So, I resorted to brute force.... took the gear and mounted atop the splined shaft and hammered the damn thing on.... took it off...moved it a few teeth and hammered it on again.... repeated this several times until the gear would slide onto the shaft with no resistance.



Replaced the gear into the housing... and guess what... the starter went right in with zero resistance.



Dry starting her with the kill switch in the off position and the motor is turning. Now I'll button her back up ( shift lever, headers, crash bars) and fire her up for real.



The real test will be after she runs for a while to see if the starter is still dragging.



I guess sometimes you just can't pussyfoot around with the thing. My guess is that the starter had never been pulled and the gear/teeth were so burred up that a little brute force was needed.
 
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