Ran into the same problem when I installed the Spyke starter clutch since the original one was slipping, there was a miss match between the starter clutch, pinion shaft, gear and the spring. this prevented the gear from coming all the way out and meshing properly with the gear on the clutch basket. I went back and bought a new stock harley starter clutch which includes the shaft spring clutch all matched and it worked perfect this is on a 1.4KW starter so the stock ones are plenty strong enough. Chewed up the ring gear on the clutch basket after only about 2 weeks before, been running the harley one for the past year on a 127" motor no problems.

 

I agree with most,most likely electrical.My wifes uncle had the same problem after buying a 95 custom softail that had been in storage for 10yrs.Come to find out the coil had dry rotted and cracked from being in storage for so long and caused the bike to fire improperly causing the teeth on the starter to shear almost immediately.Replaced the coil and did thurough check of the rest of the electrical and I believe had found a ground also that had broken,fixed both problems and hasnt had a problem since.

 

I had a similar problem last year where the starter would sometimes run freely without engaging while other times it would grind and destroy the gear teeth on the starter motor shaft. (I replied to someone else who was experiencing the free-running problem with his starter too) Anyway, I ended up replacing the stater drive for my '86 5 speed but you may have the same problem since I believe the same starter drive is used on your model. The part number I replaced was 31443-65B, and it costed me $62 for the part.

 

Do you have a BDL belt drive or closed primary??

 

hello to all,

finally figured out the problem with starter, My starter housing keeps getting loose i guess ill have to get a new inner primary and starter housing