98 EVO Starting (HOT)

I recently purchasd a 98 FXDL with 7800 miles. I am having trouble with the starter kicking out and grinding when I try to start it after the engine is warmed up? It works fine when the engine is cold. Could there be a misalignment problem after engine warm up and all parts have expanded or maybe a starter/flywheel gear problem. Would the Primary Chain cover need to be removed in order to access the starter/flywheel gear? I would appreciate the help.

Low Rider,

After reading on this website for a few months, I can tell you that one of the first responses is going to be "buy the service manual, it is the best investment you will ever make for you bike".

I have bought the manual for the last 6 bikes I've owned, even though I don't generally make major repairs myself. It just gives me such a better understanding of my bike and also makes routine service (which I do perform) so much simpler and more accurate.

Good luck! Be safe!

Manual

I purchased a repair manual a few days after the bike. I have used the info for servicing the fluids and spark plugs. I was needing some insight from anyone that may be experiencing ( or have experienced ) the same problem? I am hoping that Harley has made the gear that engages the flywheel the sacrificial component?? I don't want to damage the flywheel. Thank you for the reply. Good riding.

Is your motor stock or with raised compression? I'd suggest you immediately invest in some quality large capacity battery cables. The Evo motors are reputed to have too small of a gauge wire to give the starter all the mechanical advantage it needs. They increased the diameter with the Twin cam motors but some people still say its not enough. Here is a technical article done here by direct parts on this subject: http://www.directparts.com/static/articles/motorcycle_gears.htm
you can find that article and many other very informative ones like how to jet your CV carb by clicking on the "Articles" link on the Direct Partsl homepage. For more info on the battery cables if you choose to try them try here:
http://www.terrycomp.com/batteries_cat.html

Starting EVO

I would suggest you do all the basic stuff first check all grounds as well as all the hot wires for corrosion and being tight check the charging system and do a load test on the battery. If all is well there and you have a stock motor no high compression or altered ignition that might be causing the starter to stall I would then look at the hard parts and yes you do need to pull the primary cover to look at the starter drive. There is a small hand full of parts that make up the drive so look at the manuel first and then the parts as you take it apart as you can install some parts backwards and not know it until you try to start the bike. Dutch

Starter

I am a first time Harley owner and appreciate the help. Thank you for the links. I had to install a new battery when I purchased the bike. Do you recommend any size CCA/RAh battery? The cables and connections didn't look corroded but I will give them a closer inspection. The engine is stock compression, at least the guy told me it was stock. It has Screaming Eagle pipes, been re-jetted (for the pipes) and a K&N air filter. The engine may be running a little lean? The porcelin in the plugs are "White" after ~ 300 miles? I also checked the timing, the marks are in the window. I don't want to damage the bike any more than it already may be?

Hard Start

I just went through the same problem with a 100" Revtech motor. It would start fine while cold but start very hard or not at all once hot. It eventually even started melting the power wire. I replaced the aluminimum ground strap with a very thick gauge cable from the local cycle shop. They didn't have one long enough for the power wire so I got a 4 gauge one from the local automotive speed shop which worked fine. It made a huge difference. Now all is well. Good Luck!

starter problem

i had the same problem with my 95 fxsts. the problem with mine was in the solenoid. the contacts were burnt and out of alignment. a bebuild kit did the trick. no more jump out of the starter.

HD nippondenso gear reduction starters

I repair approx 2 to 5 HD starters a week during the summer months. The main problems they seem to have is ...worn contacts in the solenoid and drive clutch slipping... I work in the shop area and dont really deal with or talk to customers very much about their bikes I just rebuild & repair starter motors of every type. my guess would be the contacts in the solenoid may be cooked. I talk about how to fix this problem without having to pull out the starter in a earlier reply i made today for "directrix" on "starter issues".....-LATER!-