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2004 XVS1100 Silverado. It has had four other owners, I am number 5. No modifications. Received the bike in the fall of 2015 and drove it around a bit. Noticed it had some starting issues and did some reading. Sounds like the Starter clutch... Looked around this forum and didn't see anything like this posted. Maybe I missed it?

During the winter I replaced the starter clutch along with the starter idler gear along with new plugs. Tried to start it. Heard it turn over once then a change in the sound of the starter. It sounded like it was struggling to turn the engine over. Tried it a couple more times and then the big change in sound. Spinning. nothing but spinning. Heart sinks.. Took it apart again and the starter idle gear is spinning with all kinds of metal filings on the bottom of the case... wreaked it. installed a new one. Same symptoms. Did manage to get it started once but not again and I don't want to wreck the idle gear. To me the starter is good as it spun the guts out of the idle gear. I have spun the motor by hand and all is good till the heads reach the top. Could the compression be too much? Could it be something in the cylinders? Not sure where to go to next.
 

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2004 XVS1100 Silverado. It has had four other owners, I am number 5. No modifications. Received the bike in the fall of 2015 and drove it around a bit. Noticed it had some starting issues and did some reading. Sounds like the Starter clutch... Looked around this forum and didn't see anything like this posted. Maybe I missed it?

During the winter I replaced the starter clutch along with the starter idler gear along with new plugs. Tried to start it. Heard it turn over once then a change in the sound of the starter. It sounded like it was struggling to turn the engine over. Tried it a couple more times and then the big change in sound. Spinning. nothing but spinning. Heart sinks.. Took it apart again and the starter idle gear is spinning with all kinds of metal filings on the bottom of the case... wreaked it. installed a new one. Same symptoms. Did manage to get it started once but not again and I don't want to wreck the idle gear. To me the starter is good as it spun the guts out of the idle gear. I have spun the motor by hand and all is good till the heads reach the top. Could the compression be too much? Could it be something in the cylinders? Not sure where to go to next.
can you spin it over the top by hand or is it locking up, as the piston is rising on compression you should hear the shiss of the air compressing and slowly leaking past the rings, if don't hear the air compressing. remove a plug and see if anything hit it indicating mechanical damage. did the engine actually run with those metal filings in it?
 

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Yes I can turn it over the top by hand and I can hear the air shiss. It never ran with the metal filings in it.
sounds like your ok then. another starter clutch should do it. they do make a heavier after market one because of so many failures but i can't vouch for how much better it is. did you stake the two timing gears the last time you did it. you have to turn turn the engine up to 11 times to line the gears up because they only line up every 12 revolutions of the engine, once they line up you stake em together with a drift or punch only then can you do the starter clutch. a least that what i'v been seeing in any videos of it being done, personally i haven't had displeasure of tackling one. yet
 

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Thanks Paul466. Yeah I did everything according to the docs on replacing the starter clutch. It was real easy to change out.. Time consuming. I am going to take the starter off and have a peek at it any way. Again thanks.
 

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Just an update to this issue. Over the weekend I removed the plugs and turned the bike over with narry a problem. Checked the compression and all is good. Wet and dry. Had a look at the plugs and they were black and sooty, ( is sooty a word??) from when I did get it going. Also, there was some popping and a few backfires going on. Did a little reading across the web and it sounds like it is running rich. So I made a small 5 to 10 degree turn on the PMS screw in the carb. So far I have started it once with out a problem. Will try again this evening. Fingers crossed.
Thanks All. :) Shiny side up.
 
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