Just completed my Winter Rebuild, and now have a starting issue:

When I go to start the bike there is a severe lag on the starter with the initial compression stroke. I have to hold the stater for what seems an eternity before it will even turn the motor over. After the initial stroke, it spins freely and will start with no problems.

Here is what i have done:

Complete engine rebuild, new crank, new pistons, jugs, SE heads and an EV27 cam. S&S Shorty E carb.
New Hi-torq starter and solenoid.

Battery is a stock HD gel battery, new in June 2007

Even after having the battery sitting on a trickle charger overnight, I have the same problem.

I have tried putting a spacer between the solenoid shaft and the primary starter shaft, and all that does is to prevent the starter from engaging on the drive ring (spacer came with the starter as a possible fix for this issue)

What have I missed?

Thanks in advance.......

 

Do you have the SE heads with the compression releases in them? If not your starter is fighting higher compression and will sooner or later lose the battle as will your battery.

Read here: http://www.hotbikeweb.com/tech/0306h...ses/index.html

Now before you do anything remove your battery and have it load tested using a MC battery tester. If it is at all weak then you might want to try a higher rated battery. Most of the HD batteries are rated at 270-280 CCA. I know interstate makes some high performance ones that are rated at 310CCA which may be enough to roll the engine over. That might solve your problem since you installed a heavier starter. If you want a HD stock battery they are made by East Penn Deka (google them). They have distributors that sell the exact HD battery usually for about $40 less than the HD one.

 

When you push the starter button, make sure there is 12V going into your starter. If there is less you may have a short. Dosn't take much, nicked, smashed, or bent wire could throw it all off.