04 Ultra, 95 Big Bore kit, cams...
I bought the bike in Sept 2009, about 20k ago. It always starts fine when cold, but when hot starting it would do the nasty compression lock. After a few times it would start. One trip something changed and it started to make a grinding sound before catching and starting, always on the hot start.

Last year on my cross country trip, it got worse. Had some other problems and took it to a dealer in Tennessee. The starter sounded terrible in the shop and both the tech and my buddy (former HD tech) said it sounded like the idler gear.

I pulled it apart a few days ago. The idler gear and ring gear look fine. No worn spots or broken teeth. All of the gears in the gear reduction look good. The clutch drive assembly only rotates one way. The only thing that looks at all suspect is the inside gear of the clutch assembly, and possibly the spiral gear on the end of the shaft that goes into the clutch assembly.

I've taken this to the dealer and an Indy and they say that looks fine also. They both recommend a new starter (of course). I want to fix the problem, not band aid it.

I've read a lot of threads here and see there's a lot of comments on the HD compensator, but that's on 07s and newer. The Indy recommended a Spyke gear reduced starter but there is some bad feedback here. I'm wide open to comments and suggestions.

 

Does it sometimes sound like the starter is slipping or not engaging? Does it sometimes make wicked noise? With out having it here to look at my first guess is a starter clutch (Bendix in a car).

 

When it doesn't start right it up, it makes an ugly, almost shrill grinding noise and then catches and stops. I haven't heard it since last fall so it's hard to explain. I've thought clutch also, but for the price of it, I'm halfway to complete new starter.

Any opinions on Spyke?

 

Sometimes starter clutches feel good until you put them in a vise and try to turn them backwards with channel locks. Just from what you are saying and not able to see or hear it I am guessing starter clutch. I can get a OEM starter clutch for mine for about $75 plus shipping from Zanotti in PA. Wish you lived closer I would be happy to help you out.

 

Really appreciate it and that's the direction I'm leaning. Thanks again.