to separate gear (19), shifter collar (20), and spacer (21) from shaft (22).

To remove starter shifter lever (25), it is necessary to either remove inner chain housing (See "Stripping Motorcycle for Transmission Repair") or remove oil tank.

Remove screw (24) and lever (25) from chain housing.

Remove starter shaft housing (29) from chain housing studs as follows:

Remove starter motor and housing as an assembly by removing nuts and lockwashers (23) from chain housing studs. (See "Starter Motor," Section 5.)

Remove oil deflector (26) and gear (28) from starter shafl housing (29). Needle bearings (30) and (31) are pressec into housings at shaft ends.

To service starter motor see Section 5.


Assembly is essentially the reverse of disassembly except as follows:

Clean needle bearings (30 and 31) and repack with grease. If replaced, needle bearing (31) should be pressed in flush with outside of housing. Pinion (19), spacer (21) and shaft (22) should be assembled with no lubrication on worm threads.

Shaft nut (16) should be secured to shaft with Harley-Davidson "Stud and Bearing Mount," Part No. 99626-77 after cleaning parts with "Safety Solvent."

Connect battery cable to longest solenoid terminal stud.

CAUTION —If cables are reversed, the solenoid will remain in battery circuit.

Figure 4-5. Starter Drive

1. Cover

13. Solenoid

23. Nut and lockwasher (2)

2. Terminal nut and lockwasher (2)

14. Pin gear and shaft

24. Shifter lever screw

3. Terminal nut and lockwasher


25. Shifter lever

4. Retainer cap

15. Thrust washer

26. Oil deflector

5. Pin

16. Pinion shaft nut

27. Oil deflector O-ring

6. Spring

17. Pinion and shifter collar

28. Drive gear

7. Bolt and lockwasher (2)


29. Starter shaft housing

8. Spacer bar

18. Lock ring

30. Needle bearing

9. Boot

19. Pinion gear

31. Needle bearing (pressed

10. Gasket

20. Shifter collar

into inner primary

11. Plunger

21. Spacer


12. Plunger spring

22. Shaft

32. Starter motor

Figure 4-6. Starter Shaft, Housing and Solenoid — Exploded View

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