Starter Clutch Replacement on 09 SG
#31
08-26-2013, 12:33 PM
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#32
08-26-2013, 01:19 PM
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If u r sure u have all the bolts out then u may have to "TAP" the starter with a rubber mallet. If I remember correctly there is a rubber o ring somewhere in that joint. It is a tight fit to keep the primary oil from leaking out. Also remove carefully as to not loose locating pin. Just take your time you'll get it
#33
08-27-2013, 06:13 AM
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Starter Clutch
Well I have to replace the starter clutch on my 09 SG as I have the dreaded hot start issues. I have a 09 SG Fuel moto stage 1 96" motor, I have ordered a SE compensator kit and will also replace that to help eliminate the issue. There are some great threads on how to replace the compensator but there is very little about replacing the starter clutch. I have been searching and reading different threads on this since last week and still not a lot of information. I have the new HD starter cluch in my garage and I also have a HD service manual which is pretty useless as far as the starter or any pictures. Do any of you guys have pictures and any suggestions on replacing it. As far as removing the starter that does not look to bad but I have no information on the actual starter clutch replacement. Thanks for any and all help!
Originally Posted by Scubamike
Ok so I went ahead today because I had time and decided I would replace my worn starter clutch in my 09 Streetglide with 25k on it and it was not starting or had the hot start grinding sound. The HD kit part number is 31633-07A which includes a new starter cluch assembly, o-ring, spring, and ball msrp about $125 from HD. I did not find a lot of information in the HD service manual but removing the starter was pretty straight forward. I disconnected the battery and for my sake just removed it. I then disconnected the positive cable on top of the starter solenoid assembly as well as disconnected the connector on the lower forward side of the starter. Removed the two securing allen bolts and gently tugged and removed the starter assembly at a upward angle. The book states to remove the oil fill cap but I did not have to. Also another caution is to make sure you do not loose the two ring dowels in the mount holes for the starter to install into the backside of the primary. Thats it for removing the starter, pretty easy. Pictured below is the new start clutch assembly.
Attachment 213112
Now the fun part to replace the starter clutch. As stated earlier in this thread I cleaned and wiped off the starter and took a knife and cut the powder coat at the seam where it comes apart to try to eliminate it flaking. Its a little hard to explain but once you have the assembly out you can kind of see what you have to do to get at it and hopefully the pictures help. Remove the chrome cap and bracket off the solenoid. If you look you will see two recessed phillips screws that you have to loosen and remove. Mine were covered in powder coat so I used a phillips socket and gently hit the bit into place and then a rachet to loosen and remove those two fasteners. Second where you removed the chrome cover and bracket on the solenoid end you have to loosen those two long fasteners holding the solenoid in place. Be carefull to lay the starter assembly on its side and not allow the solenoid assembly to come apart or the brushes can drop out of place. Just loosen the two fasteners and leave that part together. Now with those four fasteners removed you can gently spit the starter assembly and see the starter clutch and the rest of the gears and pieces. Also be careful that there is five roller type bearings that are loose inside the center of the smaller gear inside a plastic retainer do not loose those. Here are a few pictures to help explain what I am talking about.
Attachment 213113
Attachment 213114
Attachment 213115
Attachment 213116
I left the solenoid part of the started sideways on my bench and cleaned that assembly. I then removed the original starter clutch assembly with a light pull. After which I removed the smalled gear with the roller bearings insided and cleaned the assembly. After which I placed a little oil around the bearing race and insearted the new starter clutch assembly in the starter housing with a gentle force and made sure it seated the bearing in the case. After which I installed the smaller gear and bearings in place. The kit gives you a new ball bearing make sure you place that inside the shaft of the new starter clutch. If you look inside the original one you will see it. Next replace the spring on the plunger assembly it just slides of and on. After that i put a little oil on the other bearing and gently slid the two haves together while leaving it on the bench as to not disrupt the solenoid brushes and I then tightened the four removed fasteners. I then installed the new o-ring on the starter that goes into the backside of the primary. After which again make sure your ring dowels are in place and reinstall the starter as you removed it and make sure to locktight and tourqe the two starter mount bolts to 22-24ft-lbs per the HD service manual. I then installed the battery and seat and tried it out and it worked perfect. I let the bike warm up and shut it of and on a few times and it again worked great. Went for a short ride to get it warmed up to operating temp stopped for gas and again it worked great like it used to. I have a new SE compensator on order and am going to change that next week as well. Also another note as I could not see any visible wear on the original starter clutch.
The starter clutch job did not take very long and if you just take your time its pretty easy to do. Maybe took about 1 1/2 hours total and thats with me screwing around and cleaning everything which I guess thats what the dealer quoted me. Sorry for the long winded post I just thought it may help somebody down the road with theirs. If you have any questions of suggestions please post or if you would like to add anything to this thread. Thanks again to the guys that posted their information and suggestions.
#34
05-17-2014, 08:19 AM
#37
05-17-2014, 10:35 AM
Well I have to replace the starter clutch on my 09 SG as I have the dreaded hot start issues. I have a 09 SG Fuel moto stage 1 96" motor, I have ordered a SE compensator kit and will also replace that to help eliminate the issue. There are some great threads on how to replace the compensator but there is very little about replacing the starter clutch. I have been searching and reading different threads on this since last week and still not a lot of information. I have the new HD starter cluch in my garage and I also have a HD service manual which is pretty useless as far as the starter or any pictures. Do any of you guys have pictures and any suggestions on replacing it. As far as removing the starter that does not look to bad but I have no information on the actual starter clutch replacement. Thanks for any and all help!
#38
05-17-2014, 12:36 PM
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I have done mine 3 times. First time I replaced the whole starter and bought an all chrome 1.4 kw from rare electrical. It worked fine for a year and then the dreaded clunk and slipping. The best solution for the problem is to always start your bike in neutral. I ended up having mcr's installed which is the ultimate answer but I still have an extra starter clutch on hand at all times. It is an easy fix and as has been mentioned,use a razor knife to score the seams on the starter to prevent chunks of powdercoat from flaking off. 
#39
05-17-2014, 12:48 PM
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#40
05-17-2014, 12:48 PM
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