October 31, 2020, 01:06:16 PM
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Author Topic: PIA Starter  (Read 155 times)

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October 12, 2020, 07:17:18 PM
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lunyty

Supporting Member
2004 ultra,was going to change the starter clutch and cannot get the starter out......i took off the chrome end cover but the starter keeps hitting the oil tank fill hole,,,do i need to clock this thing or what ?? had to walk away before the bullets flew....any help appreciated...done many starters over the years,Pan ,Shovel ,Evo never had trouble like this......i had a service manual but borrowed it out (i know )  never to be seen again

October 12, 2020, 08:09:42 PM
Reply #1
Online

HDBitchin

Administrator
My 2008 Touring Manual says the following about removing the starter. It shouldn't be any different on your 2004 model year.

1. Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. Remove starter front and rear mounting screws with captive
washers.
4. Remove Keps nut from stud of bracket tab and remove
exhaust support bracket.
5. Pull back rubber boot and remove hex nut from battery
post. Remove battery positive and main power cable ring
terminals.
6. Remove starter solenoid connector at front of starter.
7. Remove engine oil filler cap/dipstick. Cover fill spout with
clean shop cloth to keep out dirt and debris.
NOTE
To facilitate starter removal, if necessary, remove two worm
drive clamps to release heat shield from rear header pipe.
8. Remove starter from motorcycle carefully sliding it out
through space between rear exhaust header pipe and side
cover. Exercise caution to avoid losing two ring dowels
loosely installed in the primary chaincase (or starter)
flange.


Since you have become a Supporting Member of the forum you do have access to the Manual Downloads section. We have a 2004 Touring service manual in that library. You might want to download that manual and check see if it has any different steps for removal on the 2004 model year. I will also download it and take a look in the morning.
HDBitchin aka Tank
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When shopping for anything look for Made in the USA and save American jobs and families

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October 12, 2020, 10:06:46 PM
Reply #2
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lunyty

Supporting Member
I knew this was my kind of group,,did not realize i had access  to the manuals being a new member...Much Thanks
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October 13, 2020, 06:40:02 AM
Reply #3
Online

HDBitchin

Administrator
Hey @lunyty good morning!!

Here is how the Starter removal reads in the 2004 manual. Looks similar...


Remove seat.
1. 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.
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.
HDBitchin aka Tank
AMA Member- Click Here to Join
When shopping for anything look for Made in the USA and save American jobs and families

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