Honestly you're talking about spending thousands of dollars and you don't even know what your compression is?? dude get to the root of the matter and figure it out, Just don't start throwing parts of money at it.. I'm only saying this cuz you don't give enough information so we're all going to speculate..

 

13:1 sounds a little crazy from up here. Maybe something else is binding up or not aligned. I agree you need to trouble shoot the issue before you spend a ton of money, that you may not need to spend. Take a deep breath and go about a good scientific method to isolate the issue. Good luck.

 

What cam is in there?
A few things to check, and try
^^^^ something binding? - it should spin fast with the spark plugs out.
Timing issue - energize solenoid with the ignition off.
Voltage drop across solenoid - check with meter, or dirty way, jump across solenoid big poles while cranking engine.
Anti Gravity battery OK and up to the task, battery cables also? - read voltage drop at battery and across cables, maybe try jumper cables straight to good ground and solenoid with a known good (big) battery. *edit*, I see you said starter burning up, could be already burnt up from trying to start with other issues, did it let the smoke out?
Lifters not pumped up, not bleeding off cylinder pressure, compression releases actually working - do a compression test, throttle wide open, if it can even crank enough to do one. Check with and without compression releases.

 

Report.

 

Had to take a step back from this entirely. Bike is just sitting in my garage for the time being. Had to make a few repairs on the truck and that takes precedence over the bike unfortunately.

Engine turns over fine without the spark plugs its only with them in there that it didn't turn over. Cam is a Woods w6h. Hadn't considered timing issue, I didn't build the engine so I figured he had sorted all that out. Being a high lift cam, I wonder if that is actually part of the problem.

Ill have to get a compression testing tool and test that along with using my multimeter to check all the electrical too.

At the end of the day though, this is a high compression 96" evo. The little hitachi starter may just not be enough for this engine.

 

Yeah, that could be an issue. My stock '96 often is very slow to overcome the initial compression and get spinning, but it's likely a wiring issue from the factory. My '99 is not stock, and it starts more consistently.

 

FWIW, my chopper has a high compression 96" S&S EVO motor. I struggled with starting until I installed a lithium battery. Now it turns over with no problem. It also lasts a lot longer.

 

do you have the correct charger for that lithium ion battery? My bike with stock compression was doing the same thing when I got it, wouldn't turn over or barely roll over but rolled over fine with plugs pulled. The battery that came with the bike was new but not taking a full charge. I swapped in a new battery and it starts right up. I have a lithium battery in my truck camper and they take a different charger than lead acid... it charges at something like 14.5v. If you don't have the correct charger and thus only a partial charge on that battery it would cause the issue you are seeing. Quick and easy test (what I did) was connect a lawn mower battery I have directly to the bike, or if you have good jumper cables (1 gauge welding wire or similar, not the cheap jumpers you get premade at the auto parts store) you can likely connect a known good or slightly larger battery and see if that changes anything. quick and easy and worth a shot.

EDIT: looked at your pics again, that battery says 12.8v so it is probably different than my li-ion. I would still definitely try to connect a known good battery and see what happens. If you have compression releases and they are working it should at least roll over with the releases opened. I had a high compression evo fxsts with the stock starter, it definitely struggled a bit but rolled over and fired up.

 

Bringing this thread back from the dead. Lots of updates that I just never had the time to post. Lots of road bumps with the project, couple major life obstacles, moved houses, but the bike is finally running. Will try to document everything that has gone on since my last update. At the end of the day, not totally sure needed to upgrade the primary, but it's done, and is just another unique thing on this bike. I couldnt be happier with how everything has turned out!

Broke the bike down again to start with upgrading the trans. Actually glad I did take this apart, I realized one of the snap rings on the trap door wasn't properly seated. Ended up having issues getting that seated and broke the lip of the trap door, so this go around I bought a zipper performance trap door. Got the late model evo gear set and splined main shaft installed in the trap door, and everything back in the case.



Got the transmission bolted back up and moved onto the primary. I picked up a twin cam outer and late evo inner, along with a Stage 1 Evolution Industries clutch and basket '98-06' model with 37 tooth sprocket and went with 84t ring and 10t pinion gears for the starter. Also grabbed their yellow springs and did half yellow half blue. Was able to reuse the diamond chain and baker comp sprocket luckily.



For the starter I went with a compufire 2kw starter I got off of Ebay, and this is where I hit my second issue. The hole on the late model evos is larger than the model I had, so I had to drill out a bigger hole in my transmission case to allow the starter mount to fit. Made a little template of the mounting bracket and got to drilling. Not perfect, but it gets the job done.








Then noticed that the trans top cover I had, was changed slightly in '91? to accomidate the starter change, so quickly ordered a new top cover and swapped that on. Also picked up a Santoro fabworx shift link, and some of their Chachos to add some more subtle red to the bike. Swapped out the normal hose clamps for some red AN fittings as well. Did a mock fit with the outer primary just to see how those red chachos looked against the gloss black.










And of course nothing can just be simple, so when I went to actually install the starter, the pinion gear was WAY out of alignment. The starter shaft was excessivley long, and the plunger didnt sit right. I took the starter apart and realized that in manufacturing, they just simply never cut the shaft to the correct size. Measured how much needed to come off and quickly fixed it with a cutoff wheel. Put the starter back together, and got that properly spaced out and installed.

To get the '08+ seat mounted, I cut a little piece of steel, bent up a tongue, and put some velcro over the end to protect the foam, and provide some thickness to the tab that slides into the seat. Very crude, and will 100% redo it, but it holds the seat from sliding. I was also noticing that the center of the seat is unsupported, and my big *** at 275+ was causing it to sink, so I also fabricated a simple brace to bolt to the old rail mounts. Just learning to weld, always had my brother to weld for me so never took the time to learn on my own 🤣 Dont judge my welds too hard. As with almost everything on this bike, its my first time, and learning as I go.

And while I was cutting and bending steel pieces, I built a little tab for the gas tank Since i no longer have the right key for that lock.








When I went to put the clutch and comp back together I noticed the crank seal was leaking, At the same time when I went to put the exhuast back on, I noticed the stud was stripped. Was unable to get the seal out, and every method I tried to get that stud out didnt work either. At this point I figured the guy that built the engine could/should help me fix these since they were technically issues from his work. Took the bike back to him early Feb, and then just kind of let him do his thing. About a month later I get a call from the shop from a lady ive never spoken to before. While he had my bike he got a new business partner, and then proceeded to ghost him and all his clients, so the new owners took on my project, and said theyd try to help me as best they can. They started early march and got those two things taken care of. Got it buttoned back up, and when they went to fire it they said the engine was pissing oil from everywher possible. Apparently the engine wasnt vented at all. They then took some time to get it properly vented, and helped me figure out my battery size and needs cause we were having some issues keeping that small battery charged. But as of yesterday the bike is back in my garage, put together, and running.

Still have some things to finish but its on the road at least. The fuel gauge, and oil pressure gauge arent currently reading, and the speedometer needs to be calibrated. I have to replace the inner fairing, becasue it fell off my lift when we had first moved and cracked it. Little stuff like that, but I can atleast say the project is finished, and I have a harley to ride! I appreciate all the help i have receieved along the way from you all too, and I appreciate you not coming for my head as I try to learn. Apologize the last little bit i didnt document better, but just did not have the time or mental capacity with all ive had going on.

 

Man you really went through a lot to upgrade 5th he starter system.. Sounds nice...