Starter problems

About a year and a half ago, my tech was finishing up some carb work on my 96 Dyna WideGlide. The starter stuck in the crank mode and couldn't be fixed. I ordered and installed an aftermarket 1.7 KW chromed starter and he replaced it. Within 10 starts the ring gear and the jackshaft gear tore up big time. We replaced the ring gear, the jackshaft kit and gear, and cleaned out all the metal in the primary, etc. This time it lasted about 15 starts and ate up the ring gear again. We replaced all the same stuff again and my tech said he thought he had gotten to the bottom of the issue?? Maybe he put the ring gear on reversed....supposedly the bevel was originally facing in but needs to be facing out?? Anyways, I have been riding the Dyna for about seven months...possibly 40 starts and yesterday the starter chewed up the ring gear again. I pulled the primary, adjuster and compensator but the clutch basket won't slide off the trans shaft....How much force does it take or am I screwing up here? Anyways I really want to fix this bike and I'm gonna do it my self if it takes a year. I just need some feedback on what is going on with this gear-eating stuff!:gah:

As has already been stated, you definitely want to use the factory service manual & I'd use a stock starter too, as I've never had a problem with one, even on an engine with 13:1 compression. But I've seen people have LOTS of problems with aftermarket units & must assume they're made with lower quality parts.

Also, if you have a place in your area that rebulds starters, alternators, etc., you can usually take a stock unit you've got in or buy one from them for less $$$ than a new one & it'll work as well as, if not better, than a new one. I used to go to a place called "Automotive Armature" & there wasn't anything starter, generator, alternator, etc. they didn't have or couldn't rebuild.

Yep, They're Nippondenso starters also called Denso, no need to go to a dealer and pay a lot more money just to have a HD part number, if there's no starter shop around here's a link for repair kits i found on the www.
Repair your Denso Starter and SAVE MONEY!!!

I appreciate the responses. I have been using my neighbor's service manual but yesterday I ordered the official Harley manual for 95 - 96 Dynas. Also following the tech tips on this web site, I have checked into retrofitting the 66t gearset...that will take the increased intial torque from the 1.7KW starter. Rebuilding the original starter was my first thought also, but my tech told me it was not repairable due to the nature of the damage?? I certainly will try and determine and check the travel on the jackshaft and any other tolerances that are critical to the engagement and release of the starter drive. In a previous response on another site, one guy had had similar problems and determined that if you tighten the jackshaft retainer nut to HD specs on the aftermarket starter it causes a distortion in the mechanism that creates some travel interferences. I guess I'll set it up by the manual and see if I can note any binding, etc. One real interesting tip I read on this site was about ignition advance and spark delay. After I get the bike running we definately have to check the advance and make sure the spark delay is working. If all this doesn't work, I'm going to install an open primary so at least all the parts will fall out instead of gringing around in the case...joke??

When you put the new ring gear on the clutch basket.The bevel edge, faces the pinoin gear.The bevel allows the gears to engage properly.Service Manual is a must have.Good luck