Hey guys, i got a custom softail with a 1340 evo only has around 8600 miles on it.. the motor is mostly stock other than a high flow filter and pipes.. im getting real bad kickback sound when i start when its hot. Sounds terrible. Ive been reading and seems like theres a million ideas on what the problem is.. also recently after all night riding it when i got home the battery was literally smoking or steaming and it was brand new. I have opened up the primary to install some custom mid controls and the jackshaft and started ring are showing signs of wear. Also primary chain was def out of spec and needed tightening.. wondering if that can cause the kickback? Any advice would be greatly appreciated.

Timing too hot

Even tho its stock? It runs fine just starter issue. Also the battery smelled like rotten eggs.

Sign the starter clutch is going out.

Seems feasible, i could change that while i got it apart.

Check the output of your rectifier.

i read about that causing the battery to overcharge but didnt do anything to my old battery it was just old and worn out yet it cooked a brand new one.. pretty crappy the starter clutch and v. Regulator could be going out and its lower mileage.

What brand of battery did you out in there? Was it a quality product, or a Chicom cheapy? Also did you inspect the battery cables, both ends?

I suspect there are two unrelated issues here: charging system; starting. Deal with each of them in turn and don't get distracted! Dr Hess has a Sticky at the top of this section, so when you can do so work your way through that, which will help you diagnose any charging problems. A hot battery may be poor connectors, a sick battery, or over-charging, hence cooking the poor thing. I only buy AGM-type batteries, which are robust and have good starting abilities.

Two unrated issues.

The smoking battery is a charging issue...as stated use the sticky to check.

From the pic of the pinion you posted...looks like a clearance issue from aftermarket parts...seen overseas primary castings do that...ring gear could also be suspect.


1: regardless of mileage it is 18 years old
2: a 12 year old with a cresent wrench could change the mileage on an evo