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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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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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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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