Warranty Checklist
There are several factors that can cause a starter to fail. These factors will cause any brand starter to fail and need to be addressed because the factors that caused the initial starter to fail will cause all replacement starters to fail.
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The following are some things to check before replacing a starter.
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Battery
Make sure the battery is fully charged. Test voltage-drop while cranking. This is done by placing the multimeter in "DC Voltage" and placing the positive lead of the multimeter to the positive terminal of the better. Likewise, connect the negative lead of the multimeter to the negative terminal of the battery. Read the voltage while cranking the starter. The voltage should not drop below 9.5 volts DC.
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Cables
Make sure cable ends are tight and secure to the battery terminals, starter and grounds. Make sure cables are not coming out of cable ends. Loose ends can cause excessive heat and amperage draw.
Note: Trigger wire must be at least 14 gauge wire.
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Starter
Is the starter clutch engaging then disengaging?
Is the starter clutch free s[inning?
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If the starter just clicks, do the following test:
Make sure battery is fully charged.
Do a voltage drop test as described above while performing the starter test.
The starter must be installed in the bike to perform this test.
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Make sure the bike is in neutral when performing this test.
Remove the trigger wire from the starter switch (plastic connector plug) of the starter. Touch one end of the jumper wire to the starter switch (plastic connector) and the other end of the jumper wire to the positive terminal of the battery. If the starter functions as normal the start is good.
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Troubleshooting:
If cranking volts drops below 9.5 DC volts, test the battery.
If starter functions during the test but not when wired normally, the issue is within the bikes wiring.
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Fuel
For 2007 and up (2006 Dyna and up) old fuel socks in the fuel tanks can cause premature starter failure. Old fuel socks will not allow proper fuel to enter the combustion chamber and the engine will not fully crank over. The next cycle it can fire early and kick back destroying the starter drive clutch.
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Compensator System
Excessive play in the compensator system can cause stress on the starter drive clutch. If excessive play in the compensator system has caused the started drive clutch to fail, it will destroy a new drive clutch and needs to be addressed.