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2003 Dyna-Starter I have 2003 Dyna and the starter needs to be replaced. Do I have to take the outer-primary off...it seems that the starter "shaft" is bolted to the inner wall of the innner-primary. Am I stuck with stripping the bike down to un-bolt the starter?

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  • afp23 Jul 26, 2008

    i had the sarter rebuilt put it back on the bike and had the same problem.i left the cover off and watched what it was doing.the gear came out like it was supposed to but it would not turn the flywheel.i think there is a keyway or a gear or somthething in the starter bad.what do you think?

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Yes you have to pull the outer primary to get to the bolts.

Posted on Jun 11, 2008

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http://www.jhchoppers.com/projects/1997_FXSTC/hot_mock/Primary%20Drive%202.jpg

(the gear above the clutch)

The gear is larger in diameter that the hole in the bearing that the shaft passes through.

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I don't understand exactly what you mean by the bearing getting "stuck" in outer primary. The starter shaft has bearing race on the of it. This bearing race is also a nut that holds the shaft and it's parts together. The outer primary cover should have either a bearing or a bushing in it. The bushing or bearing in the outer primary provides support for the starter shaft while starting the engine.

Now, take the starter shaft fork loose and remove the shaft. Put the shaft into the bearing or bushing and make sure it turns freely. If not, you'll need to take the shaft and the outer primary to an automotive machine shop and have the bushing fitted to the "nut" on the end of the shaft. If you have a bearing in the outer primary, the nut must be turned down to fit it but neither of these cases are common, matter of fact, I've never heard of it having to be done.

If the "nut" on the outer end of the shaft seems to fit the bearing or bushing in the outer primary like it should, then your problem is an alignment problem. The outer primary, inner primary, and starter assembly are not aligned. There should be a couple of alignment pins in the inner primary that aligns the outer primary when installed. There are also two alignment pins in the starter gear housing on the backside of the inner primary. You may have to remove these pins in order to get everything to align properly.

Welcome to the world of foreign made Harley parts. Regrettably, we have to rely on foreign made parts to keep the older bikes running. Not all the parts fit like they should. I once spent three days trying to get a set of kick starter gears to work on a 72 FLH. I never did get them to work but managed to use the clutch gear to repair the transmission but I had to modify it to get it to work.

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