Tutorial: Change the Harley-Davidson starter engine step by step

In this practical article we will perform step by step the replacement of the starter engine on a Harley-Davidson motorcycle.
Although it may seem a complex operation, especially because it implies the opening of the primary transmission crankcase, we will see that it can be done with “normal” manual tools and only requires following the workshop book of the model in question and a bit of patience.

The choice of a good candidate
When we have definitely proven that the machine's starter has reached the end of its useful life and we decided to replace it, we can use the original replacement, or by practically the same price to improve this component a bit.
If, for example, our model has the typical 1.2 kW original engine, we can resort to AFTERMARKET manufacturers and find a 1.4 kW substitute, more power and ease of starting due to a similar economic disbursement.

It is important to know that if we use a more power starter engine it is not always necessary to install a greater capacity battery, but it is essential that it is in good condition and also verify the condition of the battery cables.

Preparing the operation
One of the keys to success in any repair is based on having the entire necessary tool and spare parts to finish the work Before starting, so we must first read and understand the procedure in the workshop manual and then verify that we have all the joints, oils and tools necessary to avoid surprises.

Obtaining access
We have chosen as an example a Softail-CAM model because it is one of the most complex to perform since it requires the extraction of the oil tank, in the other models it will be enough to remove the exhaust to have access to the engine.
Security always goes ahead, so we will begin by disconnecting the battery terminals to avoid problems. In the case of this model we will also extract it from the motorcycle, since it is located inside the oil tank.

Before extracting the oil tank, we will empty it by taking out the drainage screw and then separate the cracks from the sleeves stretching from them.

Then we will disconnect the oil lines, pressing slightly in the fastening clips and smoothly pulling out (important to mark or remember where each takes to reassemble them correctly).

We continue extracting the protective plastic from behind the fender and loosening the 2 screws that hold the oil tank behind.

We only have to release the front support of it and we can extract the deposit.

Working at Primary
We continue the process draining the primary transmission crankcase by taking the screw from under the clutch cover.
We will loosen the primary lid screws and remove it, leaving the starting pinion.

This pinion is subject to the starter engine by means of a small and long screw blocked by a tongue that we will fold to unscrew it.
Once we have a loose pinion

We can already disconnect the cable from the battery,

Loosen the 2 screws that hold behind the starter engine and extract it.

Before riding the new engine in its location we will clean the entire contact zone with the rear of the primary crankcase, since it is essential for its proper functioning because this union makes electric mass of the starter engine.

Assembly and verification
We will make the assembly in the reverse order to the extraction, paying attention to the tightening pairs and without forgetting to fill the corresponding oils.
After checking that there are no leaks and everything is in its place we only have to press the start button and enjoy the "magic" of electricity.

Frank Burguera

#mecanicaharley