Instructions for Replacing a Harley Road King Starterby Jill Davis
If your Harley-Davidson Road King starter is problematic and has failed to pass the starter draw test, you must remove it, inspect it for faults, clean it and then reassemble it. Check the Harley owner's manual for inspection instructions and to find out whether you can repair the starter or need to buy a new one. If you have performed Harley repairs in the past and have the right tools, you can likely accomplish the removal and installation yourself.
Remove the negative battery cable from the battery terminal before beginning any other work.
Locate the starter front mounting screw on the right side of the Road King, and remove it with a Phillips screwdriver. Remove the starter rear mounting screw and washer.
Locate the Keps nut, and remove it from the stud of the bracket tab with a socket wrench.
Remove the exhaust support bracket.
Pull on the rubber boot for access to the hex nut. Remove it from the battery post using a 5/8-inch hex wrench. Remove the main power cable ring terminals and the positive battery cable.
Locate the starter solenoid at the front of the starter, and remove it.
Locate the oil filler cap, at the top of the transmission case on the right side of the motorcycle, and rotate it counterclockwise to remove it. Place a clean rag on top of the fill spout to keep out dirt and debris.
Slide the starter carefully from the motorcycle through the space between the rear exhaust header pipe and the side cover. Do not lose the two ring dowels installed in the primary chain case flange; you must install them for the next step.
Lightly oil the O-ring on the starter and bore of the primary chain case using chain case lubricant.
Slide the starter carefully in through the space between the rear exhaust header pipe and the side cover. Move the starter into its installed position, with the starter solenoid connector at the front.
Remove the cloth from the fill spout, and install the oil filler cap/dipstick.
Locate the slot on the exhaust support bracket, and install it onto the stud of the bracket tab. Align the holes with the holes in the starter flange. Begin rotating the Keps nut on the stud.
Install the starter front mounting screw and washer while engaging the hole in the exhaust support bracket. Install the starter rear mounting screw.
Tighten the starter front and rear mounting screws.
Tighten the Keps nut on the stud of the bracket tab.
Reinstall the battery positive cable ring terminal onto the battery post. Install and tighten the hex nut.
Pull on the rubber boot to cover the terminal connections.
Reinstall the starter solenoid connector at the front of the starter.
Reinstall the negative battery cable to the battery terminal.