Mate has a 97 FLSTC, just recently started having trouble starting, has a grinding noise and occasionly will start after this noise (second hit on the button) 

Sounds to me like the jackshaft is grinding on the flywheel without engaging. After some ideas as to what to look for. I am thinking a worn bush/bearing where the jackshaft goes into the outer primary. I videoed the noise but cant load it. Any ideas appreciated. Cheers Burnzi (and young Jake the owner)

Not mine Cooky young plumbing apprentice getting started the right way (on a harley) Starter has just been rebuilt and should be fine.

If in doubt, pull it out,
test its arse to make sure it lasts,
If it's fucked, it goes in the bin,
go buy another, and bolt it in,
Test again and all is well,
Get on the fucker and ride like hell!

Friendly bit of poetry for yo Mr Burnz!

Hahahaha good one, think you may have missed your calling mate

worn ring gear on the clutch basket or  the pinion gear on the jackshaft pull the outer primary and have a looksee

Battery is brand new (but I havnt checked the output), good points on the ring gear and the jackshaft. I have a spare pinion gear assembly here but its a different shape to his. Will pull the outer primary off this weekend maybe.

I'm thinking, if starter has just been rebuilt. just maybe the starter itself, is NOT linede up with the ring gear. might need to loosten up starter mount bolts, and line it up right. tighten it all see it that fixes it. hope it does.

 

If its grinding then i would expect to see some damage on the gears at the end of the starter and/or the clutch ring gear. What do they look like?

Missing teeth on ring gear (or worn). Hope they put the correct pinion on the starter when it was rebuilt. Why was it rebuilt to start with? You'll sort it out.

 

who re-built it?

return it and tell them there's a problem houston 

 

Burnzi, sounds like the (starter clutch )could is on its way out, usually this part is the first to give up, being small & taking the brunt of the engagment, mine gave up in coffs harbour(1989evo) & l push started it till getting to Sydney, the HD shop there didn't have one, but would in 3 days if l wanted to wait, & cost $360.00 fitted, My Ass!!! l push started it till l got back home here to Melbourne, bought the starter clutch on line delivered for $42,, took a hour & half to fit ,

 yep! I recon its the starter clutch.  Ive had two go and they sounded like that before they gave up.  genuine kit was about $100 i think and came with seals and lock washer .  $40 ish on fleabay. job isnt hard. just take ya time when u split the starter. primary has to come off( tc88) to get the jack shaft undone.  About 3 outa 10 on the hard scale.