Harley Davidson 2005 touring models. Service repair manual — page 18

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Connect fuel vapor vent tube to fitting at top of canopy.

CAUTION

Slide head of console mounting bolt into slot at top of

Exercise caution to avoid pinching the wiring harness

canopy.

between the fuel tank and vehicle frame. Wire damage

Moving instrument console toward installed position,

may result in electrical problems.

install fuel level sender connector [141], 3-place Mini-

Deutsch, at top of canopy. Bend flexible clamp to capture

Start fuel tank front mounting bolts (with flat washers)

main harness conduit.

into left and right side of frame.

Align hole in instrument console with console mounting

Install bolt (with flat washer) to secure rear of fuel tank to

bolt and place into position on fuel tank.

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Start fuel tank front mounting bolts (with flat washers)

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

into left and right side of frame.

27 Nm).

Install bolt (with flat washer) to secure rear of fuel tank to

Connect fuel vapor vent tube to fitting on filler neck of

frame backbone. On FLHRS models, capture instrument

fuel tank.

console bracket during installation. Tighten bolt to 15-20

ft-lbs (20-27 Nm).

Remove filler cap. Position console on canopy. Route

cables from beneath console as shown in Figure 4-18.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

Be sure that hoses and wires are not pinched by the con-

27 Nm).

sole during installation. Reinstall filler cap.

Install acorn nut at top of instrument console and tighten

Install Allen head screw to fasten rear flange of console

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phil-

to clip nut on fuel tank weldment. Tighten screw to 25-30

lips screw and large flat washer (absent on FLHRS mod-

in-lbs (2.8-3.4 Nm).

els). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

10.

Connect fuel gauge to main harness. Route pin housing

Open fuel door on console. Install two Allen head screws

and convoluted tubing forward and then inboard between

to secure front of console to clip nuts on canopy bracket.

front of crossover hose fitting and bottom of fuel tank.

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Mate pin and socket halves of fuel gauge connector

Connect fuel tank harness connector [13], 3-place Mul-

[117], 4-place Multilock. Feed connector into tunnel of

tilock, in front of battery. See Figure 4-16.

fuel tank. See Figure 4-19.

10.

Snap anchor of new cable strap into hole on left side of

11.

Snap anchor of new cable strap into hole on left side of

frame backbone. Tighten cable strap capturing main har-

ness bundles, fuel level sender conduit, and fuel vapor

ness bundle, instrument console conduit, and fuel vapor

vent tube. Cut any excess cable strap material.

NOTE

Route fuel overflow hose inboard of wire bundles on right side

of frame, but do not capture in cable straps. See Figure 4-18.

12. Insert bolt through battery negative cable (black) into

11. 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. Install seat. See Section 2.24 SEAT, INSTALLATION.

12. Install seat. See Section 2.24 SEAT, INSTALLATION.

FLHR/S

Remove wooden blocks and move fuel tank toward its

installed position. Half way down, move fuel tank cross-

over hose in front of ignition coil. Work fuel tank into posi-

tion aligning front flange holes with those in frame.

CAUTION

Exercise caution to avoid pinching the wiring harness

between the fuel tank and vehicle frame. Wire damage

may result in electrical problems.

4-26

2005 Touring: Fuel

HOME

EVAPORATIVE EMISSIONS CONTROL SYSTEM

4.8

● When the engine is running, negative pressure

CALIFORNIA MODELS ONLY

(vacuum) draws the fuel vapors stored in the char-

coal canister through the purge tube to the carbure-

GENERAL

tor (or induction module) where they are burned as

part of the normal combustion process.

Harley-Davidson motorcycles sold in the state of California

● On carbureted models, fuel vapors emanating from

are equipped with an evaporative (EVAP) emissions control

the carburetor throat are drawn to the charcoal can-

system. In conformance with California Air Resource Board

ister through the clean air inlet tube connected to

(CARB) regulations, the EVAP system prevents both fuel and

the inboard side of the air cleaner backplate. Crank-

crankcase vapors from escaping into the atmosphere. See

case vapors passing from the breather tubes into

Figure 4-20.

the air filter element follow the fuel vapors to the

charcoal canister. These vapors, after passing

The EVAP system functions as follows:

through the charcoal canister, also travel through

the purge tube to the carburetor where they are

● The fuel vapor vent tube connected to a fitting on

burned.

the filler neck (top of canopy on FLHR/C/S models)

allows fuel vapors in the fuel tank to be vented

● When the engine is not running, the gravity-oper-

through the vapor valve to the charcoal canister. If

ated baffle plate at the air cleaner air inlet port

the motorcycle is tipped, the vapor valve also pre-

closes to prevent fuel and crankcase vapors from

vents the loss of gasoline through the vent tube.

escaping into the atmosphere.

Filler Neck Fitting

Vacuum

(Top of Canopy on FLHR/C/S)

Tube

Carburetor

Fuel

Tank

Clean Air

Inlet Tube

Fuel

Fuel Vapor

Valve

Vapor

Vent Tube

Valve

Purge

Tube

Air Cleaner

Fuel Vapor

Backplate

Vent Tube

Charcoal

Canister

f1706x4x

Figure 4-20. California Evaporative Emissions Control System (Carbureted Models)

2005 Touring: Fuel

4-27

HOME

1WARNING

Vent

Verify that the evaporative emissions tubes/hoses do not

Tube

contact hot exhaust or engine parts. Tubes/hoses con-

135˚

tain flammable vapors that can be ignited if damaged,

Elbow

possibly causing fire or explosion which could result in

death or serious injury.

Vapor

Valve

TROUBLESHOOTING

Arm

The EVAP system has been designed to operate with a mini-

mum of maintenance. Check that all tubes/hoses are cor-

Hole

rectly routed and properly connected. Also, verify that the

tubes/hoses are not pinched or kinked.

VAPOR VALVE

Cable Strap

Small

Slot

f2184x4x

NOTE

On 49 State models, the charcoal canister is absent and the

Figure 4-21. Vapor Valve Mounting Bracket

bottom tube of the vapor valve is vented to the atmosphere.

REMOVAL

From right side of bracket, insert end of small cable strap

Remove seat. See Section 2.24 SEAT, REMOVAL.

(P/N 10065) through hole in arm and then around body

Remove left side saddlebag. See Section 2.25 SADDLE-

of vapor valve. Mate ends of cable strap and pull tight

BAG, REMOVAL.

engaging strap in slot of arm. Cut any excess cable strap

Gently pull side cover from frame downtubes (no tools

material. See Figure 4-21.

required).

Install free end of 135˚ elbow onto neck at top of vapor

Locate vapor valve attached to frame cross member in

valve.

front of battery box (left side). See Figure 4-21.

Verify that vapor valve is completely vertical. Momen-

Cut cable strap to release vapor valve from mounting

tarily push on top of vapor valve to verify that it returns to

bracket.

the completely vertical position.

Remove 135˚ elbow from neck at top of vapor valve.

On California models, raise vapor valve slightly and pull

1WARNING

hose fitting on vent tube from bottom fitting on vapor

valve.

Verify that the vent tubes do not contact hot exhaust or

engine parts. Tubes contain flammable vapors that can

NOTE

be ignited if damaged, possibly causing fire or explosion,

On 49 State models, just pull out vapor valve with bottom vent

which could result in death or serious injury.

tube attached. Remove hose fitting on vent tube from bottom

fitting of vapor valve.

5. Recheck bottom vent tube routing to be sure that hose

fittings are not pinched or kinked, and that there is no

contact with the drive belt. For California models, see

INSTALLATION

Figure 4-23.

Hold vapor valve in its approximate position on left side

On 49 State models, verify that vent tube at bottom of

of mounting bracket (with long necked end at the top).

vapor valve is routed through opening above fuse block

On California models, install hose fitting on vent tube to

bracket (upper weldment between downtubes) to out-

bottom fitting of vapor valve.

board side. Orient vent tube so that it runs downward

NOTE

along the back of the forward frame downtube, where the

On 49 State models, attach hose fitting on vent tube to bot-

free end is then tucked into opening at front of lower

tom fitting on vapor valve. Insert vapor valve through opening

weldment (containing side cover grommet).

above fuse block bracket (upper weldment between down-

6. Align barbed studs in side cover with grommets in frame

tubes), and hold in its approximate position on left side of

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

mounting bracket.

4-28

2005 Touring: Fuel

HOME

7. Install left side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

Left Side View

8. Install seat. See Section 2.24 SEAT, INSTALLATION.

PURGE TUBE

Fuel Vapor Vent Tube

To Carburetor or Induction Module

CHARCOAL CANISTER

CARB.

TANK

REMOVAL

1. Remove rear fender. See Section 2.33 REAR FENDER,

REMOVAL.

Fuel Vapor Vent Tube

From Filler Neck of Fuel Tank

1WARNING

Via Vapor Valve

f1063b9x

Always disconnect the negative battery cable first. If the

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion, which could result in death or serious injury.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3. Unthread bolt and remove battery positive cable (red)

from battery positive (+) terminal.

4. Using a T40 TORX drive head, loosen bolt to move lip of

Top View

hold-down clamp off edge of battery. Remove battery

Clean Air Inlet Tube

from battery box.

From Air Cleaner Backplate

on Carbureted Models Only

Reaching into battery box, pry plastic retaining pin out of

hole on left side. See inset of Figure 4-22.

Reaching in between battery box and right side frame

member, pull clean air inlet tube (to air cleaner backplate

Retaining Pin

on carbureted models) from fitting on right side of char-

coal canister. On fuel injected models, pull 90˚ elbow

connector from fitting.

Figure 4-22. Charcoal Canister

Moving to rear left side of motorcycle, center a flashlight

on drive belt and direct the beam forward. Note the two

tube connections on the left side of the canister. See

Moving to rear right side of motorcycle, attach clean air

inlet tube (to air cleaner backplate on carbureted mod-

Figure 4-22. Reaching in between battery box and frame

member, pull tubes from canister.

els) to fitting on right side of canister. On fuel injected

models, install 90˚ elbow connector with the free end

8. With the handle of a rubber mallet, rap canister toward

pointing down.

left side of motorcycle until tongue at top of canister is

NOTE

free of grooves in bottom of battery box. From right side

of motorcycle, pull canister out of opening between bat-

The clean air inlet tube is absent on fuel injected models.

tery box and frame member.

Place battery in battery box, terminal side forward.

INSTALLATION

WARNING

1. With tongued side up, slide canister into cavity using

opening between battery box and right side frame mem-

Always connect the positive battery cable first. If the

ber. Start tongue into grooves on left side of battery box.

positive cable should contact ground with the negative

Push the canister toward the right side of the motorcycle

cable installed, the resulting sparks may cause a battery

until fully engaged. Snap plastic retaining pin into hole at

explosion, which could result in death or serious injury.

bottom of battery box (left side) to lock position of canis-

Insert bolt through battery positive cable

(red) into

ter. See inset of Figure 4-22.

threaded hole of battery positive (+) terminal. Tighten

2. Attach tubes to fittings on left side of canister. Install the

bolt to 60-96 in-lbs (6.8-10.9 Nm).

purge tube to the carburetor (or induction module) onto

Insert bolt through battery negative cable (black) into

the top fitting stamped “CARB.” Install the fuel vapor vent

tube from the fuel tank (via the vapor valve) to the bot-

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

tom fitting stamped “TANK.”

2005 Touring: Fuel

4-29

HOME

Clean Air Inlet Tube

From Air Cleaner Backplate

on Carbureted Models Only

Fuel Vapor Vent Tube

From Fuel Tank

Purge Tube

To Carburetor

or Induction Module

Fuel Vapor Vent Tube

From Vapor Valve

f1884x4x

Figure 4-23. Charcoal Canister Tube/Hose Routing (Left Side View)

Rotate hold-down clamp so that the lip (with rubber pad)

Fuel Vapor Vent Tube:

rests on the edge of the battery. Using a T40 TORX drive

head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

From bottom fitting on left side of charcoal canister (stamped

“TANK”), vent tube is routed forward and then upward in front

Install rear fender. See Section 2.33 REAR FENDER,

of battery box to bottom fitting on vapor valve mounted to rear

INSTALLATION.

of upper frame crossmember.

Another section connected to top fitting of vapor valve follows

the inboard side of the main harness bundle, where it is cap-

Charcoal Canister Hose Routing

tured in anchored cable strap on left side of frame backbone

before passing under console pod/instrument console to fit-

ting on filler neck of fuel tank (top of canopy on FLHR/C/S

1WARNING

models).

Verify that the vent tubes do not contact hot exhaust or

engine parts. Tubes contain flammable vapors that can

be ignited if damaged, possibly causing fire or explosion,

Clean Air Inlet Tube:

which could result in death or serious injury.

From 90˚ elbow connector on right side of charcoal canister,

clean air inlet tube runs forward under frame crossmember

Purge Tube:

and then upward (inboard of starter connections) following

angle of crossmember, where it is routed over crossover pipe

From top fitting on left side of charcoal canister (stamped

and rear cylinder rocker cover into tunnel of fuel tank on right

“CARB”), purge tube is routed forward where it runs under

side of frame backbone. Tube turns right just to the rear of the

frame crossmember, and then angles upward between cross-

top engine mounting bracket, where it connects to fitting on

member and inner primary housing. Captured in clip

inboard side of air cleaner backplate.

anchored in hole at front of crossmember (rear and inboard of

cruise hole), purge tube goes over crossover pipe, runs along

NOTE

left side of rear cylinder rocker cover and into tunnel of fuel

The clean air inlet tube is absent on fuel injected models, so

tank. It then crosses to right side of motorcycle just to the rear

the fitting on the right side of the canister terminates in a 90˚

of the top engine mounting bracket, where it connects to a fit-

elbow connector (the free end pointing down).

ting on the carburetor (or induction module). See Figure 4-23.

4-30

2005 Touring: Fuel

Table Of Contents

ELECTRIC STARTER

SUBJECT

PAGE NO.

5.1 Specifications

5-1

5.2 Starter System

5-2

5.3 Starter Relay

5-4

5.4 Starter

5-6

5.5 Starter Solenoid

5-13

5.6 Starter Jackshaft

5-14

NOTE

See the 2005 ELECTRICAL DIAGNOSTIC MANUAL

(Part No. 99497-05) for all SYSTEM DIAGNOSIS and

ELECTRICAL TROUBLESHOOTING information.

HOME

SPECIFICATIONS

5.1

STARTER

TORQUE VALUES

Item

Specification

Item

ft/in-lbs

Thru-bolts

39-65 in-lbs

4.4-7.3 Nm

Free (no load) speed

3000 rpm (min.) @ 11.5 V

End cover mounting

50-60 in-lbs

5.6-6.8 Nm

Free (no load) current

90 amp (max.) @ 11.5V

bracket

Stall torque

8.0 ft-lbs (10.8 Nm) @ 2.4 V

End cover center screw

90-110 in-lbs

10.2-12.4 Nm

Battery cable terminal

60-96 in-lbs

6.8-10.9 Nm

bolts

SERVICE WEAR LIMITS

Starter front and rear

14-18 ft-lbs

19-24 Nm

mounting screws

Oil filler spout allen head

Item

IN.

84-132 in-lbs

9.5-14.9 Nm

socket screws

Starter jackshaft bolt

60-80 in-lbs

6.8-9.0 Nm

Brush length minimum

0.433

Solenoid terminal nut

70-90 in-lbs

7.9-10.2 Nm

Commutator diameter

1.141

minimum

2005 Touring: Starter

5-1

HOME

STARTER SYSTEM

5.2

The magnetic forces of the pull-in and hold-in windings in the

GENERAL

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 starter is made up of an armature, field winding assem-

the same time, the main solenoid contacts are closed and

bly, solenoid, drive assembly, idler gear, and drive housing.

battery current flows directly through the field windings to the

The starter motor torque is increased through gear reduction.

armature and to ground. Simultaneously, the pull-in winding

The gear reduction consists of the drive pinion on the arma-

is opened.

ture, an idler gear, and a clutch gear in the drive housing. The

The current continues flowing through the hold-in winding,

idler gear is supported by rollers and the clutch gear is part of

keeping the main solenoid contacts closed. At this point the

the overrunning clutch/drive assembly.

starter begins to crank the engine.

The overrunning clutch is the part which engages and drives

the clutch ring gear. It also prevents the starter from overrun-

After the engine has started, the pinion gear turns freely on

the pinion shaft through the action of the overrunning clutch

ning. The field windings are connected in series with the

armature through brushes and commutator segments.

which prevents the armature overrunning by the rotation of

the clutch ring gear.

The starter relay is a non-repairable part and must be

replaced if it malfunctions.

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

Operation (Figure 5-1)

solenoid plunger is returned to its original position by the

return spring, disengaging the pinion gear from the clutch

When the starter switch is pushed, the starter relay is acti-

ring gear.

vated and battery current flows into the pull-in winding and

the hold-in winding, to ground.

5-2

2005 Touring: Starter

HOME

STARTER AT MOMENT STARTER SWITCH IS CLOSED

Armature

Field winding

Brush

Idler gear

Ball

bearing

Pinion

Plunger

gear

Main

contacts

Hold-In

Overrunning

Pull-In

winding

Clutch

clutch

winding

ring gear

Battery

Start

circuit. See

wiring

diagram.

STARTER DURING CRANKING

Armature

Field winding

Brush

Idler gear

Pinion

Ball

gear

bearing

Plunger

Main

contacts

Overrunning

Hold-in

Pull-In

winding

Battery

Clutch

clutch

ring gear

Start circuit.

See wiring

diagram

Figure 5-1. Starter Operation

2005 Touring: Starter

5-3

HOME

STARTER RELAY

5.3

REMOVAL

FLHR/C/S

Brake Light

FLHR/C/S

Relay [124]

Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

Gently pull side cover from frame downtubes (no tools

required).

Depress latches on maxi-fuse holder and then slide

cover rearward to disengage tongue from groove in fuse

block cover.

Starter

Relay [123]

Pull fuse block from tabs on mounting panel. Tabs on

f2210x8x

panel fit into slots on each side of fuse block cover.

NOTE

The fuse block cover also serves as the spare fuse holder.

Check the wire tags for positive

FLTR, FLHT/C/U

One spare 10 amp and 15 amp fuse are provided.

identification of relays. Starter

relay can be positively identified

by heavy gauge Green wire.

Remove the fuse block cover. Raise lipped side slightly

to disengage slots from tabs on fuse block.

Starter

Ignition Keyswitch

Pull relay from slots in fuse block. See upper frame of

Relay [123]

Relay [126]

Figure 5-2.

FLTR, FLHT/C/U

Remove seat. See Section 2.24 SEAT, REMOVAL.

Locate the starter relay installed in cavity of frame cross-

member at rear of battery box. See lower frame of Fig-

ure 5-2.

3. Place a finger on the rubber molding to hold it in posi-

tion, 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 identi-

fied by heavy gauge Green wire.

Remove harness connector from bottom of relay.

f2192x8x

INSTALLATION

Figure 5-2. Locate Starter Relay

FLHR/C/S

4. Slide maxi-fuse cover forward to engage tongue in

1. Install new relay in fuse block.

groove of fuse block cover and then insert maxi-fuse

holder into cover until latches engage.

2. Slide cover over fuse block until slots fully engage tabs

on block.

5. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

3. Slide fuse block into position on mounting panel. Tabs on

required).

panel fit into slots on each side of fuse block cover.

5-4

2005 Touring: Starter

HOME

6. Install left side saddlebag. See Section 2.25 SADDLE-

FLTR, FLHT/C/U

BAG, INSTALLATION.

Install harness connector at bottom of new relay.

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

push on relay until seated in cavity of frame cross-

member.

Install seat. See Section 2.24 SEAT, INSTALLATION.

2005 Touring: Starter

5-5

HOME

STARTER

5.4

REMOVAL

f2268x8x

Frame Hole

Frame

Cruise Cable

Cross Member

Routing Only

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

1WARNING

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

Positive

Unthread bolt and remove battery negative cable (black)

Battery Cable

from battery negative (-) terminal.

Remove the primary chaincase cover. See Section 6.5

PRIMARY CHAINCASE, REMOVAL, steps 3-8.

Bend tab on lockplate away from head of jackshaft bolt.

Holding pinion gear to prevent rotation, remove the jack-

shaft bolt with lockplate and thrust washer.

Negative

From right side of motorcycle, remove starter front

Battery Cable

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.

Main Power

To Maxi-Fuse

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.

Figure 5-3. Battery Cable Routing (Right Side View)

Depress external latch and pull solenoid connector from

top of starter housing.

From right side of motorcycle, tilt starter and work into its

installed position. Starter output shaft coupling must

Locate oil filler plug/dipstick on right side of motorcycle

remain on shaft and mate to starter jackshaft. See Sec-

at top of transmission case. To remove the oil filler plug,

tion 5.6 STARTER JACKSHAFT, if necessary.

pull steadily while moving plug back and forth.

Install oil filler plug/dipstick at top of transmission case

10.

Remove the starter from the right side of the motorcycle,

on right side of motorcycle.

carefully sliding it through the space between the

Install slot of exhaust support bracket onto stud of

exhaust pipe and side cover.

bracket tab aligning other holes with those in starter

NOTE

flange. Start Keps nut on stud.

If necessary, remove allen screw and decorative chrome

Engaging hole in exhaust support bracket, install starter

cover to facilitate starter removal.

front mounting screw with lockwasher. Install rear

mounting screw with lockwasher (and battery negative

11. Remove the coupling from the starter motor output shaft,

cable ring terminal) in the same manner.

if necessary.

Alternately tighten starter front and rear mounting

12. Before disassembly, perform tests on the assembled

screws to 14-18 ft-lbs (19-24 Nm). Tighten Keps nut on

starter. See DISASSEMBLY, TESTING AND REPAIR in

stud of bracket tab.

this section.

Install battery positive and main power cable ring termi-

nals onto starter post. Install flange nut and tighten to

70-90 in-lbs (7.9-10.2 Nm). Pull down rubber boot over

INSTALLATION

terminal connections on starter post. See Figure 5-3.

Snap solenoid connector to terminal at top of starter

Inspect the retaining ring within the output shaft coupling

housing.

for damage or distortion. Replace as necessary. With the

NOTE

counterbore on the outboard side, install the coupling on

If removed, install allen screw to fasten decorative chrome

the starter motor output shaft, if removed.

cover to starter.

5-6

2005 Touring: Starter

HOME

1. Field wire

15. Drive assembly/overrunning clutch

2. Thru-bolt (2)

16. Idler gear

3. Field coil

17. Idler gear bearing & cage

4. End cap

18. O-ring

5. End cap screw (2)

19. Spring

6. Brush spring (4)

20. Shaft

7. Brushes

21. Return spring

8. Brush holder

22. Ball

9. Armature

23. O-ring (2)

10. Armature bearings

11. Drive housing mounting screw (2)

12. Lockwasher (2)

13. Drive housing

14. Solenoid housing

f1107axx

Figure 5-4. Starter

9. Slide lockplate and new thrust washer onto jackshaft

12. Install the primary chaincase cover. See Section 6.5

bolt, if removed. Insert bolt into jackshaft bore.

PRIMARY CHAINCASE, INSTALLATION, steps 20-31.

10. Insert key on lockplate through slot in thrust washer and

into keyway on jackshaft. Thread the jackshaft bolt into

13. Insert bolt through battery negative cable (black) into

the starter shaft making sure that the lockplate key

threaded hole of battery negative (-) terminal. Tighten

remains in the keyway.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

11. Holding pinion gear to prevent rotation, tighten jackshaft

bolt to 60-80 in-lbs (6.8-9.0 Nm). Bend tab on lockplate

14. Install seat. See Section 2.24 SEAT, INSTALLATION.

against flat of bolt head to secure.

2005 Touring: Starter

5-7

HOME

3. See Figures 5-7 and 5-8. Remove the end cap screws

DISASSEMBLY, TESTING AND

and cap.

REPAIR

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

3500

3497

Figure 5-7. Remove End Cap Screws and O-Rings

Figure 5-5. Remove Thru-Bolts

3501

See Figures

5-4 and

5-6. Remove thru-bolts

(2).

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

3498

Figure 5-8. Remove End Cap

4. See Figures 5-4 and 5-9. Disengage brush springs (6)

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

3502

Figure 5-6. Remove Field Coil and Cap

Figure 5-9. Remove Brush Holder

5-8

2005 Touring: Starter

HOME

Commutator

Starting groove in mica

Undercutting mica with piece

with 3 cornered file

of hacksaw blade

Mica

Segments

Wrong way

Right way

Mica must not be left

Mica must be cut away

with a thin edge next to

clean between segments.

segments.

Figure 5-10. Undercutting the Mica Separators

Check the brush length. Brushes less than 0.433 inch

(11 mm) long should be replaced.

CAUTION

Do not use sandpaper or emery cloth on commutator.

NOTE

The abrasive grit may remain on commutator segments

●

Replace brushes in sets of four only.

and could cause excessive brush wear.

●

Field coil and brush holder brushes are attached to field

10. See Figure 5-11. Check for SHORTED ARMATURE with

coil and brush holder. To replace brushes, replace field

a growler. Place armature on growler. Hold a thin steel

coil and brush holder.

strip (hacksaw blade) against armature core and slowly

turn armature. A shorted armature will cause the steel

See Figure 5-4. Remove armature (9).

strip to vibrate and be attracted to the core. Shorted

armatures should be replaced.

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

2231

a lathe. Commutators should be replaced when diame-

ter is less than 1.141 in. (29.98 mm).

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 cop-

per dust.

See Figure 5-10. If an undercutting machine is not avail-

able, undercutting can be done satisfactorily using a thin

hacksaw blade. After undercutting, lightly sand the

armature with crocus cloth to remove any burrs.

Figure 5-11. Shorted Armature Test Using Growler

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5-9

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11. See Figure 5-12. Check for a GROUNDED ARMATURE

13. See Figure 5-14. Check for GROUNDED FIELD WIND-

with an ohmmeter or continuity tester. Touch one probe

ING with an ohmmeter or continuity tester. Touch one

to any commutator segment, and the other probe to the

probe to the frame, and the other probe to each of the

armature core. There should be no continuity (infinite

brushes attached to the field winding. There should be

ohms). If there is any continuity the armature is

no continuity (infinite ohms). If there is any continuity at

grounded and should be replaced.

either brush, the field winding(s) are grounded and the

field frame should be replaced.

Figure 5-12. Grounded Armature Test

Figure 5-14. Grounded Field Test

12. See Figure 5-13. Check for OPEN ARMATURE with an

14. See Figure 5-15. Check for OPEN FIELD WINDING with

ohmmeter or continuity tester. Check for continuity

an ohmmeter or continuity tester. Touch one probe to the

between all commutator segments. There should be

field wire, and the other probe to each of the brushes

continuity (0 ohms) at all test points. No continuity at any

attached to the field coils. There should be continuity. If

test point indicates armature is open and should be

there is no continuity at either brush, the field winding(s)

replaced.

are open and the field frame should be replaced.

Figure 5-13. Armature Open Test

Figure 5-15. Open Field Test

5-10

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15. See Figure 5-16. Test BRUSH HOLDER INSULATION

with an ohmmeter or continuity tester. Touch one probe

f1540a5x

to holder plate and the other probe to each of the posi-

tive (insulated) brush holders. There should be no conti-

nuity (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.

f1541x5x

Figure 5-18. Drive Housing Assembly

Figure 5-16. Brush Holder Insulation Test

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

3506

See Figure 5-4.

NOTE

Spring (21) and ball (22) are loose in shaft gear end. See

Figure 5-4.

Figure 5-19. Clutch Assembly

17. See Figures 5-4, 5-17 and 5-18. Remove the two drive

housing mounting screws

(11) and washers

(12).

Remove drive housing (13) from solenoid housing (14).

18. See Figures 5-4 and 5-19. Remove drive (15), idler gear

(16) and idler gear bearing (17) from drive housing (13).

O-ring (18) is in groove in drive housing.

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

f1557x5x

Figure 5-17. Remove Drive Housing

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Lubricate armature bearings (10) with high temperature

ASSEMBLY

grease such as LUBRIPLATE 110. Install armature (9)

and field coil (3) to solenoid housing (14).

See Figure 5-4. Replace O-rings (18, 23).

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

(7) and brush holder (8).

CAUTION

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

Do not use solvents to clean drive assembly/over-run-

Install thru-bolts (2).

ning clutch (15). It is lubricated and sealed. If you use a

solvent to clean it, the lubricant will be washed out and

Connect field wire (1) to solenoid terminal. Tighten sole-

the clutch will fail.

noid terminal nut to 70-90 in-lbs (7.9-10.2 Nm).

Clean, inspect and lubricate drive assembly compo-

nents. Lubricate parts with high temperature grease

such as LUBRIPLATE 110.

When installing drive assembly components, open end

of idler bearing cage (17) faces toward solenoid.

When installing drive housing (13) to solenoid housing

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

(21) and ball (22).

5-12

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STARTER SOLENOID

5.5

2. Remove cover and gasket. Discard gasket.

GENERAL

3. Plunger can now be removed from solenoid housing.

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 bat-

ASSEMBLY

tery, the magnetism produced pulls the plunger into the coil.

The plunger moves against two main switch contacts, closing

the circuit.

Replace wire connection hardware as necessary.

Apply a light coat of Lubriplate® 110 to plunger shaft.

DISASSEMBLY

Install plunger in solenoid housing.

See Figure 5-20. Remove screws and washers. Clip

Install new gasket. Place cover in position and install

comes off with screw.

screws, washers and clip.

Cover

Clip

Gasket

Screw and

Washer

Plunger

Solenoid

Housing

CAUTION

Do not tighten the inside nut without

removing other items shown. Movement

will cause damage to the contact.

f1079axx

Figure 5-20. Starter Solenoid

2005 Touring: Starter

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