I own a 97 FLSTF – Fat Boy custom and this thing has gone through 3 high torque performance starters in the past year. As far as performance parts it got the following on it Big-Bore Kit, Performance Ignition, S&S Carbs, and Vance and Hines Pipes. In the past I just drop it off at the local bike shop and had them replace the starter, but after 3 replacements it is obvious this is the symptom of the problem not the source. I have begun to suspect that the source of the problem maybe due to a degrading battery and or the timing is advanced too much. My thoughts are that the starter engages, but the battery doesn’t have enough power to completely turn the motor over. This causes the motor to recoil/kick back just like the old kick-starts, which puts more stress on the starter and burns it up. The other idea is that the timing is advanced too much, which causes the motor to recoil/kick-back cause the same symptoms on the starter as the week battery theory. I was hoping to see if anyone else has experiences a problem like this and what they did to resolve it. I’m sick of replacing starters.

 

Voxmorgan,

Make sure that your battery cables are clean and in good shape. Make sure that your motor is grounded to the frame. Also have the battery load tested to make sure it holds up under the draw of the bike. Good luck.

 

Big Bore? What compression are you runin you might need relases and how do the teeth look when you take off the primary.

 

I agree with DILLIGAF. It seems that there is an excessive current draw through the starter circuit. Poor grounding would definately cause that. That would also put a lot of strain on your battery. If it is your original battery, it's probably about cooked by now, and is only compounding your problem. You could also hook up an ampmeter and see what the current draw is across the starter when it is engaged.

 

Thanks for all of the feedback I will mention the grounding issue to the mechanic and double check it when I get it back home. Not sure what the engine compression is the cylinder compression is 185psi. I don’t believe the teeth were worn at all, but then again I didn’t see them (the mechanic never mentioned it though)
Cheers,
Vox