I have a 2002 FXDWG with a big motor. I have had to replace 5 starters or parts to those in the past 3 years. In the past 3 months I've had it in to have the starter pinion gear replaced with a one piece gear and the ring gear replaced again.....There seems to be some mis alignment and nothing that the shops have done fixes the problem......

What do I have to do to fix this problem?

I have put in a High Torque starter
Put in High compression release valves
Replaced the Pinion gear with a one piece Pinion gear

What else is there to do?

 

Probably need to shim the starter to get it lined up for angle and depth.

 

I just had the starter replaced under warranty one week ago on my stock 2009 Ultra Classic. I had a high output 1.4 kw starter to replace the original one.

 

Just installed SE heads w acr to hopefully solve starter issues. Dealer said not to worry about the starter when the stage 2 was installed. Seems he was wrong. It starts much easier now.

 

I put a Drag Specialties 2.0kw in mine after killing the stock one. Sounds like an air starter now