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Starter removal

Discussion in 'Motorcycle Tech Talk' started by JACKWAYNE, Dec 30, 2013.

  1. JACKWAYNE

    JACKWAYNE Member

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    I have a 2003 Roadking FLHR. I am trying to remove the starter & got it unbolted but can only move it about a 1/4 inch. Need help with removal procedure please.
    Thank you.
  2. hotroadking

    hotroadking Super Moderator Staff Member

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    You have to remove the outer primary cover
    the starter jack shaft has a bolt that has to be removed from that side

    If you don't have one get the Service Manual from the Dealer
    it will detail every item and how to RNR the part.

    Primary Removal, you should not have to go through all this, but it
    shows you the clutch basket



    THis gives you the general idea on everything you need to do, and if you skip to 2:26 you'll see the starter jackshaft bolt and how to remove it, don't worry that it's a dyna in the video the starter and stuff is the same.
    JACKWAYNE likes this.
  3. bambidee

    bambidee Active Member

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    darn you thought that should be an easy job, not like your typical automotive application with the drive inside the primary. we all live and learn, good luck
    JACKWAYNE likes this.
  4. JACKWAYNE

    JACKWAYNE Member

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  5. hotroadking

    hotroadking Super Moderator Staff Member

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    It's not difficult but there are several steps involved....

    Without the SM working on the bike is not as simple
    and you will either miss hidden bolts/nuts or break something
    trying to force it off, the $ for the SM is worth every penny
    if you wrench your own ride.
    JACKWAYNE likes this.
  6. joshbob

    joshbob Well-Known Member

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    JackWayne, if you're having trouble posting replies, see: Using this Forum - Help and Feedback.

    The SM is the best tool in your arsenal.
    JACKWAYNE likes this.
  7. cardboard

    cardboard Well-Known Member

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    The newer one don't have the jackshaft and are easier to remove.
    JACKWAYNE likes this.
  8. JACKWAYNE

    JACKWAYNE Member

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    Thanx everyone for the replys. Got the manual. The reading begins.......
  9. hotroadking

    hotroadking Super Moderator Staff Member

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    He has an 03 so unless the Harley fairy flew over and changed it for him, he's got the original style..

    Jack it's not too difficult, more time consuming,

    Tip.
    1) Drain Primary
    2) put down paper towels, rags, catch pan etc
    3) remove rear shift arm and peg
    4) Remove rear bolt on front floorboard (or take off the floorboard)
    and push the whole assembly down at the rear and out of the way.
    5) using allen socket and wrench pop each of the primary cover bolts loose
    6) Remove the torx bolts (4) from the inspection port cover 2 long, 2 short (if you know which are the two long, just remove them leave the short ones so you don't have to get a new gasket.
    7) using power cordless drill with allen wrench remove the screws, be sure to
    hold onto the cover when you pull the last bolt, it may pop right off, if not a good dead blow hammer to pop it loose is good, don't take a screwdriver and try and pry it off, the surfaces need to mate to seal it up when done.
    8)remove gasket, clean up fluids, have beer,
    9) note the starter jackshaft gear above the clutch basket,
    10) push gently back on the retaining clip on the bolt, (might as well buy a spare, last thing you want is to be doing this friday night at 9pm before a planned ride and bust the retaining tab)
    11) I get a set of large plyers and gently hold the gear, you can put a rag on the gear but you have to hold it , then back off the bolt, it's about 5 inches long
    12) now you can remove the starter, there is a coupler in there so take the starter straight out and note the position of the coupler, it has to go back on the same way.

    Reverse to install refill fluids.
    Marc1340 and JACKWAYNE like this.
  10. JACKWAYNE

    JACKWAYNE Member

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    Thanx Hotrodking. The manual I got said you have to remove the rear exhaust pipe for the starter to clear.
  11. joshbob

    joshbob Well-Known Member

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    Again, don't forget to REFILL fluids LOL.
  12. hotroadking

    hotroadking Super Moderator Staff Member

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    yeah you'll have to do that too since the left rear pipe goes over the starter on the 03

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