Motorcycle Repair: 66 Shovelhead, starter shaft, starter clutch

Question
QUESTION: Hi Mike,
I have a 66 Shovelhead that I am getting back to good working order. I have installed new points, battery, new helicoil for the front head plug, battery, etc.

I noticed that there is a loud knock during the electric starting process. I noticed it before I re-installed the head. Now, after re-installing the front head, it is very loud. The engined turns with the kickstart. The only thing that I can think of is a bad starter.

I removed the primary cover to inspect and did not "see" anything unsual. This is my first Harley project. I appreciate any input you can give.

ANSWER: Have you had the bike running? Does it make the same noise when running?
Mike

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QUESTION: Thank you for the reply,

I have not had it running. It does not make the sound when I TRY to use the kick start.
It is backfiring and trying to start. Honestly, I was afraid to continue trying the electric start in fear of damaging the bike.

I took the starter off and it all looks good. So, I guess I will put it back on....

ANSWER: Go ahead and start the bike with the kick starter and see if it knocks and let me know. If it starts knocking, shut it off as soon as you hear it
Mike


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shaft through-hole   QUESTION: Well,I can't get it started with the kick start. However I have been able to locate the noise. It is coming from the inside the primary near the starter gear. I have also noticed:
-the hole that the starter shaft passes through is not round and there is no o-ring where I believe one should be.
- there is a gouge on the inside of the primary cover that matches the ring where the pins for the starting fork ride in.
- the starter is not original. It appears to be from a 73- it has an AMF logo (this is a 66)
- the starter clutch seems to be fine.

I believe there is an alignment issue and the shaft is sloppy when installed.

Does this sound right? have you seen this before? I have read where the shaft length matters and that the length changed after 1970 or so?

Answer
You might have the incorrect shaft. The shafts for your bike runs 65-69 and then there was a change. There should be a o-ring in the back of the starter housing. Your starter is probably correct. The Prestolite starter was used from 66-81. Also, I would check the starter shaft gear for damage as well as the gear on the starter. Make sure the spacer in on the end of the shaft when putting it together. Also check the bearing inside the starter shaft housing and the one in the primary cover
Good luck and happy riding
Mike