Question about 2005 Harley Davidson XL 1200 C Sportster Custom

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How to remove starter from a 2005 sportster custom

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Disconnect the positive battery cable. Drain the primaary and remove the derby cover. Take the spirng and the locknut out. Go to the bottom of the primary cover and loosen the lock nut on the primary chain adjuster and back the adjust out a good little bit. Remove anything that's in the way of the primary cover and remove all the bolts in the outer cover. Turn the clutch adjuster clockwise as your remvove the cover.

On the other side of the bike, disconnect the positive battery cable from the starter and remove the exhaust from the bike.

Back on the left side of the bike, remove the two bolts just above the clutch assembly. They are different lengths so remember which goes where.

Reassembly is the reverse of the disassembly. When you put the outer primary back on, turn the screw counterclockwise until you can put the bolts back into the primary cover. Once all of them are in and tight, turn the screw counterclockwise as far as it will go and then go back clockwise 1/4 turn. Put the locknut, spring, and derby cover back on the primary. Adjust the primary chain by turning the screw inwards until you have 5/8" to 1/2" inch of up and down play on the chain. Feel of it throught the upper inspection hole. Once finished, add one quart of primary lube to the primary.

Good Luck
Steve

Posted on Oct 02, 2010

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