Check this page. I don't know what year/model bike you have, but here's a starter breakdown for the bike I used to own..

http://partsfinder.onlinemicrofiche....=170&b=13&c=35



31 31553-94 STARTER, COMPLETE 1 319.00 264.99 32 31600-90 SPRING, RETURN 1 1.99 1.49 33 31604-91 STARTER REPAIR KIT 1 56.49 46.99 34 31660-90 DRAIN VENT 1 1.99 1.49 35 31661-90 SPRING, BRUSH 4 36 31662-90A BOOT, INSULATING 1 3.99 3.49 37 31663-90 CLUTCH, STARTER 1 38 31664-94 SHAFT, OUTPUT 1 44.99 36.99 39 31688-90 COVER, SOLENOID 1 4.49 3.99 40 31689-90 BOLT W/ WASHER 3 1.99 1.49 41 31692-90 SPRING 1 1.99 1.49 42 31693-90 CLIP, CA95BLE 1 43 31695-90 O-RING 2 2.00 1.99 44 33126-94 LOCKPLATE 1 1.99 1.49 45 33127-94 SHAFT, EXTENSION 1 92.99 77.49 46 33449-94 SPRING, PINION 95GEAR 1 1.49 1.49 47 60647-94 COUPLING 1

 

Yep. But I still don't see how the starter clutch would make this noise or produce such an intermittent problem.
This being said, if the starter is to be taken out for inspection, the primary cover should go off anyways. At that point Custom96 can just crank it over and over (I guess) till he reproduces the problem. Then he can see - if the starter and the clutch gears are fully meshed - then it is an internal gearing issue. If not - the push relay is faulting somehow...

 

You remove the outter support for the jackshaft when you remove the primary cover.

I guess if the starter clutch was to slip some, it might make the pinion jump out.

But more likely #33 in traildogs picture, plunger and contact kit.
OP can remove solenoid cover and check the condition of contacts and plunger for high resistance from pitting or burning.

 

And it can be cleaned up with a flat file. You can get about 2 filings out of them before they need to be replaced if thats the issue.

 

In theory - yes, you loose the front jackshaft support, in practice - I always check 'em this way if everything works correctly before putting the primary cover on, and it always works !

But before messing around with the primary side, definitely, just check the plunger and connectors. As a good add-on at this point would be a pushbutton door ($15 or so on ebay).

 

If you fire the engine off without the cover, the oil that comes out the chain and clutch makes a helluva mess,..... don't ask.

 

Been there done that.

He understates the mess by the way.

 

That's true. My apologies. For me the oil usually was long gone, hehe...
One more reason to meticulous inspection / testing the solenoid side before opening up the primary.

 

Wish I coulda been there for that.................:icon _dance-twist:

 

so, I pulled the battery today and put on a load tester. it idled at 12.5volts and under load dropped to 11.5v then went back to 12.5v. when removing the battery I notice that the positive side was not as tight as it should/could be. so upon re-installing I snugged them down good. Hopefully that makes a difference.

Now,I'm not exactly sure where the starter thing is on the bike that you are referring to in said picture . Also, it doesn't really do it 'all the time' just once in a great while, Is this a simple adjustment/fix I can do I my own if need be?