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Ever since I put my chopper together in 2007 the starter intermittently makes a horrible high pitch grinding noise when trying to engage. Sometimes it happens three or four times in a row and sometimes I can go for a while without a problem. The bike is an old Drag Specialties Bike-in-a-Box so everything is aftermarket. When it first happened the shop loaned me a cutaway outer primary and it worked perfectly (of course). I've been living with it for over 9000 miles in 15 years. Today I opened it up to see what I can see. Checked the bendix by hand, it turns only one way. The other way I can turn the starter. I have a cut-down outer primary from a 95 softail but the starter gear bushing is smaller than my gear so I can't try that approach. Here are pictures that show disassembling the starter gear bolt. I was told it's a hybrid bolt for early/late starter and/or jackshaft. Does that sound right?
I can push the gear off center with a little resistance.
Bolt and washer disassembly.
The gold washer has a step worn into it. I flipped it over when reassembling.
I was told the bolt is a hybrid old/new.
My outer primary bushing is bigger than one from a 95 Softail. What years look like mine?
This is what my starter looks like, pardon all the pollen.
I'm coming to you for advice for anything to do before I pull the starter. I think the bendix is in the starter, can it be serviced/replaced separately? What years starter is this? Thanks, Joe
Sounds like the clutch inside the starter let go, common with that style and easy to replace. There were two drive tooth styles in the primary the evo years, I suspect it's a post 94 starter but don't hold me to that I can't remember the detail in dates and the changes.
The starter motor assembly is '94-up. Pre '94 used 1/4-20 bolt, '94 up uses 10-32 bolt is why you have that homemade thru bolt.
Just guessing, I'd say everything else from the starter motor itself outboard is '90-'93 stuff. But beware if you try to make everything more like it should be - '89 used some different (outer) parts from '90 or' 94 style. I'd have to go to the book to tell you exactly which ones but the pinion, jack shaft for sure are different 89/90.
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Starter Problems
