Question about Harley Davidson FLHR-FLHRI Road king Motorcycles

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I need instructions on how to change the Stator for a 2005 RoadKing Custom FLHRSI.

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1. slide rubber boot back on clutch cable and loosen lock nut and adjust the cable until there is plenty of slack. You can check the slack by moving lever when it moves and there is no tension it is ok.

2. Drain oil from primary. Drain plug is located under clutch area. Then remove the the outer cover bolts as well as the 4 in the middle for the chain access. Loosen jam nut in clutch hub center. Now remove snap ring and remove adjuster plate. Put bike in 5th gear.
Next, apply the rear brake. Use a stap to keep brake applied. The nut is 1 1/8th and is left handed. You will need to loosen adjuster for primary chain. Remove the two smaller bolts and the the plate will swing up to allow removal of chain.

3. You now need a 1 1/2 socket to remove front comp nut, the nut is right handed. You will need a large breaker bar to remove. You will also need a old screw drive as you can use the handle to lock into the chain and sprocket to keep engine from rotating. ( they make a special plastic tool but in a pinch the screw drive handle trick works fine.) Remove nut .

4.Now grab both fron comp sprocket and rear hub and they slide off the as a unit. Pay attention to order and placment of items on crank out put shaft.

5. Now bend tab on the starter jack shaft and remove small bolt, this unit will slide off, again pay attention to order of parts as there are several here. Now remove all the bolts inside the primary, and the two out side of the primary at front of case. There are two 1/4 in allens that you need to remove from right side of bike. The are holding the starter tot he trans/primary. You can leave them in place once lossened. Now the inner will slide off.

6.The rotor can be removed by hand it is a bit tough as the magnets are stong but it slides off. Then remove the screws holding the stator in place.and pull connector back through the case.

Install is same in reverse order.

NOTES/TIPS: Use some lube on rubber plug for stator when installing.
Blue loctite on all inner and outer primary bolts 18-22 ftlbs tq on inner bolts
outer cover bolts blue loctite and tq is 110 INlbs
TQ on front comp nut is 165 and red loctite
TQ on clutch hub is 70-80 ftlbs & red loctite

You will need to replace the two seals in the inner primary and you will need a
Engine to inner o-ring and a outer primary gasket and 1 qt fluid.

Once done you need to readjust clutch& chain You can adjust
the chain before installing the out. You need 5/8 -7/8 deflection
in the middle of chain.

Clutch adjustment as follows: turn adjsutment in center of clutch
until it lightly bottoms back off 1/2 -1 turn( I like 3/4) lock the
to stop adjuster from moving. Then you take up the slack in the
cable with the adjuster on the cable leave a 1/8 play in cable
housing to clutch perch.

Posted on Sep 03, 2010


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