Once every 6-10 starts I got an awful grinding noise while engaging the starter on a warm motor, It never happens when cold on the first start of the day. After it does the grinding or banging I'll hit the starter button again and it fires right up. Of course it will usually do it when some one is around... I did some pokeing around with google and people seem to suggest a starter clutch/lose wire...

The bike is a 98 FLHR. I'll pull the primary to see what the clutch basket gear and jackshaft gear looks like this week.. Its all orginal with 9,600 miles.

 

Starter clutch or battery going bad (load test it).

I'm on my 4th starter clutch on my '98 w/ 120,000 miles.

 

I'm not sure how old the battery is so i will load test it first (however it resides on a tender most all the time) but it is a terrible noise when it does it..

 

Would you reccomend the all ***** starter clutch or is a stock HD replacement ok?

 

Never tried the All *****.

 

Do just use stock HD replacement clutch?

I also ruled out the battery,

Voltage was 12.68, rated at 385 CCA & tested at 606 CCa

I went and got the primary gaskets, oil and exhaust gaskets today HD wanted 140 for the starter clutch. I didnt buy that from them,, I also had some white powder like corrosion where the main wire from the battery hooks to the starter, not a lot but some... could that be all it really was? I still have to look in the primary and if i'm going to do that i might as well pull the starter and change it anyway. It is 17 years old

 

Yes, I used the HD part.
My fault, I assumed you had checked or serviced the cables.
You do mean pull the starter and replace the starter clutch, right? EVO starters don't get replaced often.

 

Yes pull and replace the clutch. You said you have been thru 3 of them, I'm just digging into it tonight

 

Check the starter ring closely look for missing teeth.

 

Will do Brad, I hope its good!