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I'm putting a new starter in my GL1200a. Have the exhaust dropped, studs out, etc, and I'm almost positive I have the starter engaged in the gear. There's only 1/8" to go before the two bolt holes line up. I think it's the O-ring that's not yet in the hole that's stopping it. I put some oil on it all before engaging it. Had it in and out 5 times now, but it seems to want a fair bit of force to go that last bit.



Anyone got experience in this job that can offer words of advice? Dare I pry on the things to force it in? Any other ideas to seat this thing?



I'm walking away from it for the afternoon before I break something. Usually helps for some reason.



Frank
 

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Did your "new" starter come with a new gear? Some cheap starters use different splines, and come with a matching gear.

Compare the splines on your old and new starters.

If you think it's the new o-ring, lube it up good and push harder!
 

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Hi Frank vH,

Make sure that your inner mating surface to the O-ring is clean and lubed. If it is not clean you will have problems and tear up your new O-ring as it catches or binds going in.

Tim.



Look Here….

 

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I agree that you should see if the gear slides onto the starter. it might have burrs on it or fit too tight. When I put mine in, the last lil bit was tighter but I wiggled it side to side while I pushed. You should not have to pry it in!
 

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You mean I can take the gear out of the bike, and try it on the starter? Is there any chance of losing the chain or something when the gear is not on the chain?
 

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"You don't need to have the bike on the side stand to remove and replace the starter, the sprocket won't fall into the engine. I've changed half a dozen starters in 1100s and 1200s and never could push the sprocket in by hand. On the center stand you are less likely to have oil slop out. "




This was a quote from Exavid in another starter related thread.....:gunhead:
 

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Stick your finger in there & lift the gear out of the chain. pull it out & check it on your starter nose for easy fit. You wont loose anything!
 

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Thanks for all your help guys. I took all your advice - cleaned the hole out, greased the O-ring, test-fit the sprocket (fit easily) and then tried again. Ultimately though, I had to use a block of wood and a few taps with a hammer to seat the O-ring and push the starter in. Got her bolted in, and put things back in shape, and she turns over like crazy now!! I'm gonna change the oil and plugs and I'll be on the road again!!



Frank
 

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right on Frank! when yer done you can ride to the Maki for a cool one!!!:alco:
 
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