So I visit the dealer and when I go to leave, the bike won't start. Nothing. Not knowing what was wrong with it, I had no choice but to leave it with the service dept. I guess there are worse places for it to break down (or so I thought). After a full month of trial and error, throwing parts at it, they decide it's the starter and replace it. It was fine for a week, but now it is making a loud grinding noise before it catches and starts. This happens mostly when the engine is already warmed up and starting up again after a stop. It did happen once when the engine was cold. Any ideas on what could be causing this? Sounds like gears mashing together. Thanks. '99 Evo Softail

 

A month of parts throwing to fix a starter? dang.

Does it grind then catch, or you have to let off the button and try again.

My softail would not throw the pinion out all the way and grind sometimes,
it would not catch when it did that, actually, I would instinctively let off the button the second it made that awful sound, and try again.

New contacts and plunger in the solenoid, I also put a shim in the jackshaft coupler to reduce the air gap between the pinion and the ring gear.

I think I set it to .100"

 

My EVO had grinding issues when starting. replaced the jackshaft and now it's all good.

 

Yep, let go when I hear the grind, then try again and usually will start up.

 

New jackshaft was one of the parts they threw at it before replacing the starter.

 

Take a look at the ring gear on your clutch hub.

 

Thanks all for the help. I'll take a look when I get a chance. Definitely NOT bringing it back to the dealer.