Replacing a starter on a 2002
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Cruiser
Joined: Jul 2015
Posts: 148
Likes: 7
From: Central Pennsylvania, USA
Replacing a starter on a 2002
The one way clutch blew up in the starter of my 2002 Road King. Gave a pop/backfire when cranking,and zing....
Starter was just replaced along with all the seals, so all the seals are good, just need to pull the starter and install a drive clutch in the starter.
I've been studying instructions, and they have you pulling the Engine drive sprocket, Clutch assembly and Primary chain as part of the starter replacement.
The question I have is: Why does the clutch assembly have to come off?
I've read the manual, and I have the Primary cover off, and am just about to start removing the clutch. No pictures I've seen show what would interfere with the starter shaft removal. Probably missing something, just not clear to me.
Question 2 - It is a fairly hot engine with compression releases, and going over the previous owners' notes, this would appear to be the 4th or 5th starter in 75000 miles. (is that excessive?) Would a 10 tooth starter gear help the starter to live a lot longer?
Starter was just replaced along with all the seals, so all the seals are good, just need to pull the starter and install a drive clutch in the starter.
I've been studying instructions, and they have you pulling the Engine drive sprocket, Clutch assembly and Primary chain as part of the starter replacement.
The question I have is: Why does the clutch assembly have to come off?
I've read the manual, and I have the Primary cover off, and am just about to start removing the clutch. No pictures I've seen show what would interfere with the starter shaft removal. Probably missing something, just not clear to me.
Question 2 - It is a fairly hot engine with compression releases, and going over the previous owners' notes, this would appear to be the 4th or 5th starter in 75000 miles. (is that excessive?) Would a 10 tooth starter gear help the starter to live a lot longer?
Tourer
Joined: Jul 2010
Posts: 284
Likes: 24
From: Belfast, N. Ireland
I think you only need access to the jack shaft via the primary, can't see why anything else needs touched....here's instruction for a 2004 RK
1. Remove seat.
WARNING
To protect against shock and accidental start-up of vehicle,
disconnect the negative battery cable before proceeding.
Inadequate safety precautions could result in
death or serious injury.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. Remove the primary chaincase cover.
4. Bend tab on lockplate away from head of jackshaft bolt.
5. Holding pinion gear to prevent rotation, remove the jackshaft
bolt with lockplate and thrust washer.
6. From right side of motorcycle, remove starter front
mounting screw with lockwasher. Remove rear mounting
screw with lockwasher (and battery negative cable ring
terminal). Remove Keps nut from stud of bracket tab and
remove exhaust support bracket.
7. Pull back rubber boot and remove flange nut from starter
post. Remove main power and battery positive cable
ring terminals from starter post.
8. Depress external latch and pull solenoid connector from
top of starter housing.
9. Locate oil filler plug/dipstick on right side of motorcycle
at top of transmission case. To remove the oil filler plug,
pull steadily while moving plug back and forth.
10. Remove the starter from the right side of the motorcycle,
carefully sliding it through the space between the
exhaust pipe and side cover.
NOTE
If necessary, remove allen screw and decorative chrome
cover to facilitate starter removal.
11. Remove the coupling from the starter motor output shaft,
if necessary.
1. Remove seat.
WARNING
To protect against shock and accidental start-up of vehicle,
disconnect the negative battery cable before proceeding.
Inadequate safety precautions could result in
death or serious injury.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. Remove the primary chaincase cover.
4. Bend tab on lockplate away from head of jackshaft bolt.
5. Holding pinion gear to prevent rotation, remove the jackshaft
bolt with lockplate and thrust washer.
6. From right side of motorcycle, remove starter front
mounting screw with lockwasher. Remove rear mounting
screw with lockwasher (and battery negative cable ring
terminal). Remove Keps nut from stud of bracket tab and
remove exhaust support bracket.
7. Pull back rubber boot and remove flange nut from starter
post. Remove main power and battery positive cable
ring terminals from starter post.
8. Depress external latch and pull solenoid connector from
top of starter housing.
9. Locate oil filler plug/dipstick on right side of motorcycle
at top of transmission case. To remove the oil filler plug,
pull steadily while moving plug back and forth.
10. Remove the starter from the right side of the motorcycle,
carefully sliding it through the space between the
exhaust pipe and side cover.
NOTE
If necessary, remove allen screw and decorative chrome
cover to facilitate starter removal.
11. Remove the coupling from the starter motor output shaft,
if necessary.
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