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[CVOSTEVE]

Here's one for you. I was traveling back from a rally in the Uk a couple of weeks ago, stopped for fuel and went to start the bike. Got a loud screech from the motor, tried a second time and the starter was dead. As I was traveling with a group of friends we managed to jump start the bike - not the easiest thing in the world to do. The bike ran perfectly, we pull in again for fuel after cruising at 90mph for about 130 miles and there's oil pouring out of the primary. I don't risk riding any further and get recovered by the AA.
So what happened? The shaft on the starter snapped (this is only a tube - not solid) It fell into the primary and bonced around in there. As the bikes under warranty everything marked is being changed - starter motor, primary cover, chain, clutch basket etc. Oh and they're changing gaskets on both cylinders from a previous oil leak.

[Rooster]

Wow, sorry to hear. This one I haven't heard of yet. Hope you get back on the road soon, good luck to you.

[erniezap]

As long as it's apart, have them install a chrome inner primary, and possibly a chrome starter.  since they have to R&R anyway, it should only cost you the price of the part(s).

[Fired00d]

As long as it's apart, have them install a chrome inner primary, and possibly a chrome starter.  since they have to R&R anyway, it should only cost you the price of the part(s).

And it will not be full price you should have to pay, only the difference to upgrade to chrome parts with install being free.

Sure wish my starter would die.

 
Ride Safe,
Fired00d
 

[Unbalanced]

In most cases they no longer swap out the whole starter due to it has become so modular that they just replace the inner guts.    Now you may have a dealer that will do it for you based on relationship, but Harley has become much strickter on this.   After 2 gut replacements they still would not replace mine with a chrome one :*(.

Haven't had any further issue since the last repair and the compression releases being fixed / replaced.

[mcdonaldroadcapt]

What a bummer!  Could it be that your electrical compression releases are not working and caused the stress on the shaft?  I do know after hard riding such as you describe, a hot recrank on the 110 needs some help from the releases.

[deucedog]

Sure wish my starter would die.

Be careful what you wish for! 

[Fired00d]

Be careful what you wish for! 

I've been wishing for 3.5 years w/no success so far. I've got until 2011 until my ESP ends, but watch it die a day after the ESP expires.

 
Ride Safe,
Fired00d
 

[barkleydog]

I had a similar situation on my 2003 serk. I was out of warranty and found out the Chrome Innie is cheaper than the standard. The parts guy said something about the castings did not need to be as smooth as the stock so the used the rejects for chroming.

I thought that seemed strange put the price was less. And it looks good and no leaks since...