5

HOME

SPECIFICATIONS

5.1

STARTER

TORQUE VALUES
Item

Item

Specification

Free (no load) speed

3000 rpm (min.) @ 11.5 V

Free (no load) current

Stall torque

90 amp (max.) @ 11.5V

8.0 ft-lbs (10.8 Nm) @ 2.4 V

SERVICE WEAR LIMITS

Item

IN.

MM

Brush length minimum

0.433

11

Commutator diameter
minimum

1.141

ft/in-lbs

Nm

Thru-bolts

39-65 in-lbs

4.4-7.3 Nm

End cover mounting

bracket

50-60 in-lbs

5.6-6.8 Nm

End cover center screw

90-110 in-lbs

10.2-12.4 Nm

Battery cable terminal

bolts

60-96 in-lbs

6.8-10.9 Nm

Starter front and rear

mounting screws

13-20 ft-lbs

18-27 Nm

Oil filler spout allen head

socket screws

84-108 in-lbs

9.5-12.2 Nm

Starter jackshaft bolt

84-108 in-lbs

9.5-12.2 Nm

Solenoid terminal nut

70-90 in-lbs

7.9-10.2 Nm

29

2003 Touring: Starter

5-1

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STARTER SYSTEM
GENERAL
The starter is made up of an armature, field winding assembly, solenoid, drive assembly, idler gear, and drive housing.
The starter motor torque is increased through gear reduction.
The gear reduction consists of the drive pinion on the armature, an idler gear, and a clutch gear in the drive housing. The
idler gear is supported by rollers and the clutch gear is part
of the overrunning clutch/drive assembly.
The overrunning clutch is the part which engages and drives
the clutch ring gear. It also prevents the starter from overrunning. The field windings are connected in series with the
armature through brushes and commutator segments.
The starter relay is a non-repairable part and must be
replaced if it malfunctions.

Operation (Figure 5-1)

When the starter switch is pushed, the starter relay is activated and battery current flows into the pull-in winding and
the hold-in winding, to ground.

5-2

2003 Touring: Starter

5.2
The magnetic forces of the pull-in and hold-in windings in the
solenoid, pull the plunger and cause it to shift to the left, so
that the pinion gear is engaged with the clutch ring gear. At
the same time, the main solenoid contacts are closed and
battery current flows directly through the field windings to the
armature and to ground. Simultaneously, the pull-in winding
is opened.
The current continues flowing through the hold-in winding,
keeping the main solenoid contacts closed. At this point the
starter begins to crank the engine.
After the engine has started, the pinion gear turns freely on
the pinion shaft through the action of the overrunning clutch
which prevents the armature overrunning by the rotation of
the clutch ring gear.
When the starter switch is released, the current of the hold-in
winding is fed through the main solenoid contacts and the
direction of the current in the pull-in winding is reversed. The
solenoid plunger is returned to its original position by the
return spring, disengaging the pinion gear from the clutch
ring gear.

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STARTER AT MOMENT STARTER SWITCH IS CLOSED
Armature
Field winding

Brush

Idler gear
Ball
bearing
Pinion
gear

Plunger

Main
contacts

Overrunning
clutch

Clutch
ring gear

Hold-In
winding

Pull-In
winding

Battery

Start
circuit. See
wiring
diagram.
STARTER DURING CRANKING
Armature
Field winding

Pinion
gear

Brush

Idler gear
Ball
bearing
Plunger

Main
contacts

Clutch
ring gear

Overrunning
clutch

Hold-in
winding

Pull-In
winding

Battery

Start circuit.
See wiring
diagram

Figure 5-1. Starter Operation

2003 Touring: Starter

5-3

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STARTER RELAY

5.3

REMOVAL

FLHR/C

FLHR/C
1.

Remove left side saddlebag. See Section 2.23 SADDLEBAG, REMOVAL.

2.

Gently pull side cover from frame downtubes (no tools

required).

3.

Pull fuse blocks from tabs on mounting panel. Tabs on

panel fit into slots on each side of fuse block cover. To
remove cover, raise latches slightly to disengage tabs on
fuse blocks.

4.

Remove relay from rear fuse block. See upper frame of

Figure 5-2.

FLTR, FLHT/C/U

Starter
Relay [123]

Brake Light
Relay [124]

f2022x8x

1.

Remove seat. See Section 2.22 SEAT, REMOVAL.

2.

Locate the starter relay installed in cavity of frame crossmember at rear of battery box. See lower frame of Figure 5-2.

Check the wire tags for positive

identification of relays. Starter
relay can be positively identified
by heavy gauge Green wire.

3.

Place a finger on the rubber molding to hold it in position, and using a needle nose pliers, carefully pull on tab
to release starter relay. Since the position of the relays
may be reversed, starter relay can be positively identified by heavy gauge Green wire.

Starter
Relay [123]

4.

Remove harness connector from bottom of relay.

NOTE

FLTR, FLHT/C/U

Ignition Keyswitch
Relay [126]

INSTALLATION
FLHR/C
1.

Install new relay in rear fuse block.

2.

Slide cover over fuse blocks until latches fully engage

tabs on blocks. Slide fuse blocks into position on mounting panel. Tabs on panel fit into slots on each side of
fuse block cover.

3.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place (no tools
required).

4.

Install left side saddlebag. See Section 2.23 SADDLEBAG, INSTALLATION.

f2016x8x

Figure 5-2. Locate Starter Relay

2.

Place a finger on the molding to hold it in position and

push on relay until seated in cavity of frame crossmember.

3.

Install seat. See Section 2.22 SEAT, INSTALLATION.

FLTR, FLHT/C/U
1.

5-4

Install harness connector at bottom of new relay.

2003 Touring: Starter

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STARTER

5.4

REMOVAL
1.

Remove seat. See Section 2.22 SEAT, REMOVAL.

1WARNING

14. Before disassembly, perform tests on the assembled

starter. See DISASSEMBLY, TESTING AND REPAIR in
this section.

INSTALLATION

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.

1.

Inspect the retaining ring within the output shaft coupling

for damage or distortion. Replace as necessary. With
the counterbore on the outboard side, install the coupling on the starter motor output shaft, if removed.

2.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

2.

3.

Remove the primary chaincase cover. See Section 6.5

PRIMARY CHAINCASE, REMOVAL, steps 3-8.

From right side of vehicle, place starter in its installed

position. Install slot of exhaust support bracket onto stud
of bracket tab aligning other holes with those in starter
flange. Start Keps nut on stud.

4.

Bend tab on lockplate away from head of jackshaft bolt.

3.

5.

Holding pinion gear to prevent rotation, remove the jackshaft bolt with lockplate and thrust washer.

Engaging hole in exhaust support bracket, install starter

front mounting screw with lockwasher. Slide chassis
ground cable ring terminal onto rear mounting screw
(with lockwasher) and install in the same manner.

6.

From right side of vehicle, remove starter front mounting

screw with lockwasher. Remove rear mounting screw
(with lockwasher) and disconnect chassis ground cable
ring terminal. Remove Keps nut from stud of bracket tab
and remove exhaust support bracket.

4.

Alternately tighten starter front and rear mounting

screws to 13-20 ft-lbs (18-27 Nm). Tighten Keps nut on
stud of bracket tab.

5.

Install battery positive cable and main circuit breaker

ring terminals onto starter post. Install locknut. Pull down
rubber boot over terminal connections on starter post.

6.

Align holes in new gasket with those in oil filler spout.

Install the four allen head socket screws to fasten filler
spout to transmission housing. Alternately tighten
screws to 84-108 in-lbs (9-12 Nm).

7.

Snap solenoid connector to terminal at top of starter

housing.

7.

Pull back rubber boot and remove locknut from starter

post. Remove main circuit breaker 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 vehicle at

top of transmission case. To remove the oil filler plug,
pull steadily while moving plug back and forth.
CAUTION

If vehicle is upright and level, some loss of engine oil will

occur as filler spout is removed. A small amount of oil
also may be lost when the vehicle is resting on the jiffy
stand.
10. Place oil drip tray beneath oil filler spout.
11. Remove four allen head socket screws to release oil
filler spout from transmission housing. Remove and discard filler spout gasket.
12. Remove the starter from the right side of the vehicle,
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.
13. Remove the coupling from the starter motor output
shaft, if necessary.

NOTE
If removed, install allen screw to fasten decorative chrome
cover to starter.
8.

Slide lockplate and new thrust washer onto jackshaft

bolt, if removed. Insert bolt into jackshaft bore.

9.

Insert key on lockplate through slot in thrust washer and

into keyway on jackshaft. Thread the jackshaft bolt into
the starter shaft making sure that the lockplate key
remains in the keyway.

10. Holding pinion gear to prevent rotation, tighten jackshaft

bolt to 84-108 in-lbs (9.5-12.2 Nm). Bend tab on lockplate against flat of bolt head to secure.
11. Install the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
13. Check engine oil and add as necessary. See Section 3.3
GENERAL INFORMATION, CHANGING ENGINE OIL
AND FILTER, steps 10-11.

2003 Touring: Starter

5-5

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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Field wire
Thru-bolt (2)
Field coil
End cap
End cap screw (2)
Brush spring (4)
Brushes
Brush holder
Armature
Armature bearings
Drive housing mounting screw (2)
Lockwasher (2)

6
23

3
23
7

9 10
14

10

21
22

16
17
20
19
15
18

11

12
13

f1107axx

13. Drive housing

14. Solenoid housing
15. Drive assembly/overrunning
clutch
16. Idler gear
17. Idler gear bearing & cage
18. O-ring
19. Spring
20. Shaft
21. Return spring
22. Ball
23. O-ring (2)

Figure 5-3. Starter

14. Start engine and carefully check for leaks around oil filler
spout.

5-6

2003 Touring: Starter

15. Install seat. See Section 2.22 SEAT, INSTALLATION.

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DISASSEMBLY, TESTING AND

REPAIR
1.

3.

See Figures 5-3 and 5-4. Disconnect field wire (1).

See Figures 5-6 and 5-7. Remove the end cap screws
and cap.

3500

3497

Figure 5-6. Remove End Cap Screws and O-Rings

Figure 5-4. Remove Thru-Bolts

2.

3501

See Figures 5-3 and 5-5. Remove thru-bolts (2).

Remove field coil (3) and end cap (4).

3498

Figure 5-7. Remove End Cap

4.

See Figures 5-3 and 5-8. Disengage brush springs (6)

and pull field coil brushes (7) out of brush holders (8).

3502

3499

Figure 5-5. Remove Field Coil and Cap

Figure 5-8. Remove Brush Holder

2003 Touring: Starter

5-7

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Commutator
Starting groove in mica
with 3 cornered file
Mica

Commutator
Undercutting mica with piece
of hacksaw blade
Mica
Segments

Right way

Wrong way
Mica must not be left
with a thin edge next to
segments.

Mica must be cut away

clean between segments.

Figure 5-9. Undercutting the Mica Separators

5.

Check the brush length. Brushes less than 0.433 inch

(11 mm) long should be replaced.
NOTE

Replace brushes in sets of four only.

Field coil and brush holder brushes are attached to field

coil and brush holder. To replace brushes, replace field
coil and brush holder.

6.

See Figure 5-3. Remove armature (9).

7.

Place armature in lathe or truing stand and check runout

of commutator. Commutators with more than 0.015 in.
(0.38 mm) of runout should be replaced or machined on
a lathe. Commutators should be replaced when diameter is less than 1.141 in. (29.98 mm).

8.

Check depth of mica on commutator. If undercut is less

than 0.008 in. (0.20 mm), use an undercutting machine
to undercut the mica to 1/32 in. (0.79 mm) deep. The
slots should then be cleaned to remove any dirt or copper dust.

9.

See Figure 5-9. If an undercutting machine is not available, undercutting can be done satisfactorily using a thin
hacksaw blade. After undercutting, lightly sand the
armature with crocus cloth to remove any burrs.

CAUTION
Do not use sandpaper or emery cloth on commutator.
The abrasive grit may remain on commutator segments
and could cause excessive brush wear.
10. See Figure 5-10. Check for SHORTED ARMATURE with
a growler. Place armature on growler. Hold a thin steel
strip (hacksaw blade) against armature core and slowly
turn armature. A shorted armature will cause the steel
strip to vibrate and be attracted to the core. Shorted
armatures should be replaced.

2231

Figure 5-10. Shorted Armature Test Using Growler

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2003 Touring: Starter

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11. See Figure 5-11. Check for a GROUNDED ARMATURE
with an ohmmeter or continuity tester. Touch one probe
to any commutator segment, and the other probe to the
armature core. There should be no continuity (infinite
ohms). If there is any continuity the armature is
grounded and should be replaced.

13. See Figure 5-13. Check for GROUNDED FIELD WINDING with an ohmmeter or continuity tester. Touch one
probe to the frame, and the other probe to each of the
brushes attached to the field winding. There should be
no continuity (infinite ohms). If there is any continuity at
either brush, the field winding(s) are grounded and the
field frame should be replaced.

Figure 5-11. Grounded Armature Test

Figure 5-13. Grounded Field Test

12. See Figure 5-12. Check for OPEN ARMATURE with an

ohmmeter or continuity tester. Check for continuity
between all commutator segments. There should be
continuity (0 ohms) at all test points. No continuity at any
test point indicates armature is open and should be
replaced.

14. See Figure 5-14. Check for OPEN FIELD WINDING with
an ohmmeter or continuity tester. Touch one probe to the
field wire, and the other probe to each of the brushes
attached to the field coils. There should be continuity. If
there is no continuity at either brush, the field winding(s)
are open and the field frame should be replaced.

Figure 5-12. Armature Open Test

Figure 5-14. Open Field Test

2003 Touring: Starter

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15. See Figure 5-15. Test BRUSH HOLDER INSULATION
with an ohmmeter or continuity tester. Touch one probe
to holder plate and the other probe to each of the positive (insulated) brush holders. There should be no continuity (infinite ohms). If there is continuity at either brush
holder, the brush holder assembly should be replaced.
Touch one probe to the non-insulated brush holders and
the other probe to the holder plate. If you measure any
resistance, the brush holder must be replaced.

f1540a5x

f1541x5x

Figure 5-17. Drive Housing Assembly

Figure 5-15. Brush Holder Insulation Test

16. Check armature bearings (10) and replace if necessary.

See Figure 5-3.

3506

NOTE
Spring (21) and ball (22) are loose in shaft gear end. See
Figure 5-3.

Figure 5-18. Clutch Assembly

17. See Figures 5-3, 5-16 and 5-17. Remove the two drive
housing mounting screws (11) and washers (12).
Remove drive housing (13) from solenoid housing (14).
18. See Figures 5-3 and 5-18. Remove drive (15), idler gear
(16) and idler gear bearing (17) from drive housing (13).
O-ring (18) is in groove in drive housing.
f1557x5x

Figure 5-16. Remove Drive Housing

5-10

2003 Touring: Starter

19. Remove spring (19) and shaft (20).

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ASSEMBLY
1.

5.

Lubricate armature bearings (10) with high temperature

grease such as LUBRIPLATE 110. Install armature (9)
and field coil (3) to solenoid housing (14).

6.

Replace brush springs (6), if necessary. Install brushes

(7) and brush holder (8).

7.

Install end cap (4) with screws (5).

8.

Install thru-bolts (2).

9.

Connect field wire (1) to solenoid terminal. Tighten solenoid terminal nut to 70-90 in-lbs (7.9-10.2 Nm).

See Figure 5-3. Replace O-rings (18, 23).

CAUTION

Do not use solvents to clean drive assembly/over-running clutch (15). It is lubricated and sealed. If you use a
solvent to clean it, the lubricant will be washed out and
the clutch will fail.
2.

Clean, inspect and lubricate drive assembly components. Lubricate parts with high temperature grease
such as LUBRIPLATE 110.

3.

When installing drive assembly components, open end

of idler bearing cage (17) faces toward solenoid.

4.

When installing drive housing (13) to solenoid housing

(14) use new O-ring (18). Be sure to install return spring
(21) and ball (22).

2003 Touring: Starter

5-11

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STARTER SOLENOID

5.5

GENERAL
The starter solenoid is a switch designed to open and close
the starting circuit electromagnetically. The switch consists of
contacts and a winding around a hollow cylinder containing a
movable plunger. When the winding is energized by the battery, the magnetism produced pulls the plunger into the coil.
The plunger moves against two main switch contacts, closing
the circuit.

DISASSEMBLY
1.

See Figure 5-19. Remove screws and washers. Clip

comes off with screw.

2.

Remove cover and gasket. Discard gasket.

3.

Plunger can now be removed from solenoid housing.

ASSEMBLY
1.

Replace wire connection hardware as necessary.

2.

Apply a light coat of Lubriplate 110 to plunger shaft.

Install plunger in solenoid housing.

3.

Install new gasket. Place cover in position and install

screws, washers and clip.

Cover

Clip

Gasket

Solenoid
Housing

Screw and
Washer

Plunger

CAUTION
Do not tighten the inside nut without
removing other items shown. Movement
will cause damage to the contact.

f1079axx

Figure 5-19. Starter Solenoid

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2003 Touring: Starter

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STARTER JACKSHAFT

5.6

REMOVAL/DISASSEMBLY
1.

7945

Remove seat. See Section 2.22 SEAT, REMOVAL.

1WARNING
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.

See Figure 5-20. Remove the primary chaincase cover.

Remove the clutch assembly, primary chain and compensating sprocket components as a single assembly.
See Section 6.5 PRIMARY CHAINCASE, REMOVAL,
steps 3-15.

Starter
Jackshaft
Assembly

NOTE
If only the jackshaft bolt, thrust washer, lockplate, pinion gear
and/or spring require servicing, then the primary chain and
clutch assembly may be left in place.

Figure 5-20. Primary Chaincase

Retaining
Ring
f1211c5x

Output
Shaft
Coupling

Keyway

Coupling
Counterbore

Spring
Jackshaft
Slot
Key

Retaining
Ring

Jackshaft
Bolt

Pinion
Gear
Tab

Lockplate

Thrust
Washer

Primary Chaincase
Bushing
Primary
Cover Bushing

Figure 5-21. Starter Jackshaft Assembly

2003 Touring: Starter

5-13

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4.

Bend tab on lockplate away from head of jackshaft bolt.

See Figure 5-21.

5.

Holding pinion gear to prevent rotation, remove the jackshaft bolt with lockplate and thrust washer.

6.

Carefully pull jackshaft assembly from the primary

chaincase bore.

7.

Remove the pinion gear from the jackshaft.

8.

Remove the coupling from the jackshaft. Remove the

spring from the coupling.
CAUTION

Do not force the output shaft coupling through the oil

seal in the primary chaincase or the resulting damage
will require seal replacement.
9.

From right side of vehicle, remove starter front mounting

screw with lockwasher. Remove rear mounting screw
(with lockwasher) and disconnect chassis ground cable
ring terminal. Remove Keps nut from stud of bracket tab
and remove exhaust support bracket.

10. Pull back rubber boot and remove locknut from starter
post. Remove main circuit breaker and battery positive
cable ring terminals from starter post.
11. Depress external latch and pull solenoid connector from
top of starter housing.
12. Remove the starter from the right side of the vehicle,
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.
13. Remove the coupling from the starter motor output
shaft.

ASSEMBLY/INSTALLATION
NOTE
To replace the jackshaft bushings and/or seals in the primary
chaincase or primary chaincase cover, see Section 6.5 PRIMARY CHAINCASE, DISASSEMBLY.
1.

Inspect the retaining ring within the output shaft coupling

for damage or distortion. Replace as necessary. With
the counterbore on the outboard side, install the coupling on the starter motor output shaft.

2.

From right side of vehicle, place starter in its installed

position. Install slot of exhaust support bracket onto stud
of bracket tab aligning other holes with those in starter
flange. Start Keps nut on stud.

3.

Engaging hole in exhaust support bracket, install starter

front mounting screw with lockwasher. Slide chassis
ground cable ring terminal onto rear mounting screw
(with lockwasher) and install in the same manner.

5-14

2003 Touring: Starter

4.

Alternately tighten starter front and rear mounting

screws to 13-20 ft-lbs (18-27 Nm). Tighten Keps nut on
stud of bracket tab.

5.

Install battery positive cable and main circuit breaker

ring terminals onto starter post. Install locknut. Pull down
rubber boot over terminal connections on starter post.

6.

Snap solenoid connector to terminal at top of starter

housing.

NOTE
If removed, install allen screw to fasten decorative chrome
cover to starter.
7.

Inspect the retaining ring within the coupling for damage

or distortion. Replace as necessary.

8.

Insert narrow end of jackshaft into shallow side of coupling until gear face contacts installed retaining ring.
(Look at position of retaining ring within coupling to
determine shallow side.)

9.

Slide spring over narrow end of jackshaft until it contacts

retaining ring.

10. Slide pinion gear over narrow end of jackshaft until it

contacts spring.
11. Slide lockplate and new thrust washer onto jackshaft
bolt, if removed. Insert bolt into jackshaft bore.
12. Gently insert jackshaft assembly into primary chaincase
so that splined end of shaft engages coupling on starter
output shaft.
13. Insert key on lockplate through slot in thrust washer and
into keyway on jackshaft. Thread the jackshaft bolt into
the starter shaft making sure that the lockplate key
remains in the keyway.
14. Holding pinion gear to prevent rotation, tighten jackshaft
bolt to 84-108 in-lbs (9-12 Nm). Bend tab on lockplate
against flat of bolt head to secure.
15. Install the clutch, primary chain, and compensating
sprocket components. Install the primary chaincase
cover. See Section 6.5 PRIMARY CHAINCASE,
INSTALLATION, steps 9-31.
16. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
17. Install seat. See Section 2.22 SEAT, INSTALLATION.