Motorcycle Repair: 91 fatboy starting problem, worn clutch, clutch basket


Question
i've got a starting problem which has gotten progressively worse. when i hit the starter button, it strains to turn over, or, it just "tat..tat..tat" without engaging. i've replaced ...- battery
            - cables (along with sepparate grnd to starter)
            -  relay
            - starter
i've tried bypassing the bike wiring harness and going straight to the starter, using a car battery. amping the starter on the bench, i get 1.5 amps. as soon as i bolt it in and hit it, i get 49 amps...this was with the plugs removed and then the primary chain off. i've compared the amp draw to 2 different h.d.s and with just the plug wires removed (to keep it from firing) they were drawing about 6 amps. i've talked to every shop and dealer around and they haven't run across this problem before. i did get advice from an "old" mechanic that said he ran across something similar which turned out to be worn clutch-basket bearings, causing enough play to cause it to bind...any suggestions? is there supposed to be any play in the clutch hub? i heard not from one mechanic and some said minimal. i do have some...    thanks for any help you can give me.
  -paul

1991 fatboy (approx. 60,000 miles)
all original except...pipes, carb, andrews ev 27 cam, and high perf. breather

Answer
First thing you need to do is make sure you have a good battery. A weak battery will cause this problem. Make sure you have a good ground also. Test the starter by running a jummper wire direct from the battery to the post on the starter where the starter relay plugs in. Does the starter turn over like it should? if it does then you either have a bad relay or the breakers are weak and need replaced. If it doenst then the starter is bad. Even though you have replaced parts, you can still have bad ones right out of the box.
Good luck and happy riding
Mike