How to remove primary cover
SOURCE: how to remove starter from ultra classic. engine
Yes, The first thing you do is disconnect the battery ,,,Harley says to pr3vent accidental starts, but if you dont, your going to short something out..... You are going to have to remove the outer primary to get to the jackshaft. Disassemble and pull the jackshaft then you can unbolt and remove the starter ,,,,,
SOURCE: TRANSMISSION SERVICING
Most are using Syn3 oil in engine, tranny, and primary.
This simplifies this, and is a decent oil.
32oz of oil in primary.
20-24oz of oil in tranny
99851-05 primary case/ trans oil(Conv Oil)
there are other brands that surpass the syn3 oil but it takes some hunting around to find a supply.
Ammsol is one such brand and they recommend.
20w50 engine
15w40 primary
75w90 tranny
Hope this is of some assistance
Ed
SOURCE: removing harley davidson ultra classic gas tank
Drain the fuel either by siphening or removing the cross over tube at the front of the tank and letting it drain that way or just block off those cross over lines and leave the fule in the tank for removal.
0) remove seat
1) drain fuel
2) undo cross over line (bottom front of gas tank.
3) shut off pet **** and remove fuel line from pet ****.
4)there should only be 2 bolts holding the tank on, one at the top front of the tank and one at the back of the tank.
All in all a pretty easy (but possibloy messy) job.
SOURCE: need to remove and install inner primary cover
You really need a manual for this job if you have never done it before. readers digest version is as follows. Drain Primary Fluid, remove outter primary cover, Remove compensating Nut its the one on the front, use a snap ring plyer on the clutch, remove the clutch adjuster nut rod plate . will come out in one piece, Remove the Chutch Hub Nut it turns opposit ( in other words tightening is loosening it) remove bolt on the chain tensioner, whole system will now pull out.
Leave the stator magnet on dont have to remove thats the silver plate up front. Remove the jack shaft bolt on the starter pull it out. Go to other side of bike remove two starter bolts you will need LONG allen..then remove all the bolts on the inner primary and remove it. If you dont understand any of this you need a manual for your bike. or any Harley FL its all the same.
SOURCE: starter removal on 2004 ultra classic harley davidson
Disconnect battery , remove the outer primary case, pull back the lock tab on the starter jackshaft, unbolt the retainer screw, then remove the two starter bolts from the right side, sometimes you need to loosen the oil tank mounts to get at these, slip the starter and coupler out as a unit, replace the coupler and jackshaft the same way they came out when the new starter goes in, install bolts , retighten the jackshaft bolt and bend over the retainer, install and fill primary case, connect battery thats it buddy
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