Starter Assembly Overview - 1979 AMF Harley-Davidson XLH1000 Ironhead Sportster

This arrangement seems to be on a lot of AMF Harleys, sometimes with the Hitachi starter which is shorter and fatter; Hitachi and Prestolite are not interchangeable as the starter housing has specific mounting holes for each, and these are not the same. Prices for aftermarket replacements are around £30-£40 for a starter clutch or solenoid, with Chinese starter motors retailing under £100.

[@secktur8279]

Im about to pull this assembly off my dads bike, so this helps a load. A while ago the engine was seized so the starter head sheered the drive gear with all the torque the motor has, and I only found that out after replacing the solenoid, relay, and motor themselves. Vids like these are really going to help the replacement. Thanks a ton!

[@jonprice1241]

Excellent content on this starter assembly functionality. Thanks for taking the time to explain and post it!

[@bigtimejc1]

You made a note about the 2 gears needing to be in line, and that you had a rogue thrush washer between the starter gear and needle bearing. In the service manual diagram it does show that thrust washer being there HD part#31501-65. I too have my starter housing apart and noted this missing, however it is baffling because when you put that washer in place, the 2 gears do not mesh fully in fact only covering half of the teeth! Upon assembling it does mention to stake the washer but not sure how as it won’t fit in the cutout around the needle bearing.

[@ImminghamIronhead]

What I found was the washer in the diagram is a dished one, and it's already pressed into the starter housing. I wrecked three armature gears before I realised an extra washer had been added at some point, and I'd been happily re-installing the extra one because that's the way it looks in the diagram.

[@bigtimejc1]

@@ImminghamIronhead ah I see, yes I can see now how that would mess it up. I ended up ordering the said part number and it just seems to be a smaller version of the brass washer that goes on the other end. What I did was tap it into the cutout for a snug fit and the gears now line up, can only test really to see how it goes. Like your videos btw keep em coming, and thanks for getting back to me.