Removing a Harley Davidson Starter Clutch: A Step-by-Step Guide

**Are you facing issues with your Harley Davidson's engine starting?** Do not panic just yet. Often, the culprit isn't the starter clutch. Instead, it could be a weak battery. However, if you suspect the starter clutch may be the problem, here’s a comprehensive guide to help you tackle it. This guide is designed to be thorough, ensuring you have the best chance of success with your repair.

DIY Fix vs Professional Help

Before diving into the repair, it's important to assess if the problem is severe enough to warrant a DIY repair. A weak battery might be causing the starter issues, so the first step is to check the battery. But if you're confident that the starter clutch is to blame, follow the steps below to remove it. Note that if you're generally unsure or inexperienced, it's always wise to seek professional assistance.

Necessary Preparations

To safely and successfully remove the starter clutch, a few preparations are necessary. Start by doing the following:

Step 1: Purchase an appropriate workshop manual. Clymer or Haynes manuals are excellent choices for detailed guidance and diagrams. Step 2: Read through the introduction pages and the relevant chapter on the starter system in your manual. This will give you an overview of the entire process and help familiarize you with any potential challenges. Step 3: Ensure you have all the correct tools for the job. Investing in high-quality tools is crucial. Cheap, flimsy tools can lead to unsafe and ineffective repairs. Step 4: Follow the detailed instructions and diagrams meticulously included in your manual. The manufacturers go through extreme lengths to ensure these instructions are foolproof for your specific motorcycle model.

Step-by-Step Disassembly Process

Now that you're ready, here’s the detailed process to remove the starter clutch:

Step 1: Disconnect the Battery Cable

Start by disconnecting the negative terminal of the battery to prevent any potential electrical shorts or damage. Make sure the battery is fully isolated for safety.

Step 2: Drain the Primary Fluid

If your model requires it, drain the primary fluid from the transmission. This can be done by removing the drain plug. Ensure the fluid is safely disposed of according to local regulations.

Step 3: Access the Starter Solenoid

For some models, you'll need to unbolt the starter solenoid from the inner primary cover. You will see two bolts holding the solenoid in place. Remove these bolts, then carefully remove the outer primary cover. Note that you may need to remove the rear exhaust pipe depending on your specific model.

Step 4: Remove the Bolts from the Starter

Once the outer primary cover is off, use a long extension on your socket wrench to access and remove the bolts holding the starter in place. Remove the starter carefully to avoid damaging any surrounding components.

Step 5: Locate and Remove the Starter Clutch

Look under the oil tank on the backside of the inner primary. Using your long extension, gently remove the starter clutch from its position. Take note of the specific location and any special tools you need for reassembly.

Conclusion

Removing and repairing a Harley Davidson starter clutch can be a complex but rewarding task. With the right preparation, tools, and guidance, you can save money and keep your motorcycle on the road. Remember, if you encounter any difficulties or are unsure, professional assistance is always an option. Happy wrenching!