Have you tried putting a 20 amp fused wire between the positive battery post and pin 30 on the relay?


Also what kind of battery are you running?
I've heard those Lithium Ion batteries need one hit to wake them up and the second push of the button actually starts the bike.

 

It's an EVO - It always starts.. What's the problem?

It's just one of those thing. Don't sweat the small ****. I'd learn to live with it.

 

Definitely an electrical sound. Like picking a guitar string and tightening the tuning peg.
Haven't gone to a larger gauge wire from the relay. Same wire as was on the original relay.

 

I have not tried that but I'll get after it.
DuraCell from Batteries +Bulbs

 

It looks like you have thrown a lot of parts at the bike, but there is no mention of any troubleshooting steps you have taken.

Certainly not all of those parts was found to be faulty during troubleshooting.

Does the starter motor try to crank the engine on the first press of the start button?

If so, then the problem could be timing.

Time to stop buying parts and start troubleshooting.

 

It hits like it's going to engage but then it makes that whine. I release the button, press it again and it fires right up. It's almost like it's encountering too much compression on the first press then cranks on the second press

 

Here are some voltmeter checks you can try to help narrow down where the problem is:

Turn ignition switch on.

Read the voltage across the battery posts (not the battery cable terminals), what is the voltage?

With voltmeter probes still touching the battery posts, press the starter button and read the voltage while the starter is cranking, what is the voltage?

Now, move the voltmeter probes:

Positive probe touching the post on the starter solenoid (not the cable terminal),

Negative probe touching the body of the starter.

Press the starter button and measure the voltage, what is the voltage while the starter is cranking?

 

How long have you owned this bike and did this just start happening or did it always do this..?

 

It's worth cking Sir

 

I had a 89 Softail did that for years. Lived with it till had a bigger issue arise. I put in a 04 starter and that issue was history.
All 89 stock wiring, nothing added.
Only difference I noted was the later starter has more KW cranking power.