starter removal 2004 road king
Cruiser
Joined: Mar 2008
Posts: 109
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From: Frackville,Pa.
RE: starter removal 2004 road king
REMOVAL
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
7[size=4]8
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. See Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 3-8.
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. See Figure 5-3.
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
If your just removing the starter start from step 6
[IMG]local://upfiles/55106/C2B3C80955AE43FE9763A3EAC629C1BC.jpg[/IMG]
Banned
Joined: Mar 2008
Posts: 1,967
Likes: 206
From: Jax FL
bumping a 10 year old thread because it looks like you no longer need to remove the primary, but i had to GOOGLE a ton of stuff to verify, this is from the other forum:
"the need to remove the primary was gone when the 6 spd arrived in 06 dyna's and 07 up bikes, remove the battery cables, unplug the solenoid wire and remove the two bolts and depending on exhaust you may have some brackets on the front or both bolts, simply pull the starter out after that. Good idea to replace the o-ring on the starter nose upon re-Assembly"
"the need to remove the primary was gone when the 6 spd arrived in 06 dyna's and 07 up bikes, remove the battery cables, unplug the solenoid wire and remove the two bolts and depending on exhaust you may have some brackets on the front or both bolts, simply pull the starter out after that. Good idea to replace the o-ring on the starter nose upon re-Assembly"
Outstanding HDF Member
Joined: May 2015
Posts: 2,172
Likes: 377
From: Georgia
bumping a 10 year old thread because it looks like you no longer need to remove the primary, but i had to GOOGLE a ton of stuff to verify, this is from the other forum:
"the need to remove the primary was gone when the 6 spd arrived in 06 dyna's and 07 up bikes, remove the battery cables, unplug the solenoid wire and remove the two bolts and depending on exhaust you may have some brackets on the front or both bolts, simply pull the starter out after that. Good idea to replace the o-ring on the starter nose upon re-Assembly"
"the need to remove the primary was gone when the 6 spd arrived in 06 dyna's and 07 up bikes, remove the battery cables, unplug the solenoid wire and remove the two bolts and depending on exhaust you may have some brackets on the front or both bolts, simply pull the starter out after that. Good idea to replace the o-ring on the starter nose upon re-Assembly"
Best advice, even 10 years later, is to buy that service manual. No Google necessary then.
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