I have a starting issue. Its an 03 FLHT Standard. Last year I had a stage 5 R&R 95" kit installed on the bike. When I got it back it had a charging issue. I replaced the voltage regulator and that fixed that. Shortly after that it began to give me starting issues. I would hit the button just to hear click. I figured the stater was weak so I replaced it with a brand new Harley starter. All seemed good or so I thought. A couple weeks later same issue. So......I replaced the battery just to be safe. Hit the button and.......CLICK. This year I replaced the starter relay hoping it was that but hit the button and click. I can hear the starter sliding over but its not turning the crank. Not sure where to go next and my local is clueless where to point me. any help would be great. Thanks

 

Have you load tested the battery when it is giving you problems? Have you replaced the battery cables? Have you tested the stator? I suspect that something happened during the 95" install.

 

Poor conductivity between the battery and the starter would produce these symptoms. With the battery connected normally, bike off, you should measure zero volts across the battery terminal and the cable going to the starter. If you measure anything but zero, you have a voltage drop at that point. (current x resistance). You can follow the same procedure between the battery terminal and the connection post on the starter. Any thing but zero volts is bad gen! Whatever the votage you might read subtracted from the battery's charged potential is what the starter is seeing for cranking. The voltage is the push for the current - less push, less current, less crank. (you need to depress the start button to provide a ground)