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?

Did you remove the starter gear inside the primary cover?

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.

Two bolts on the right hand side of the bike hold the starter body to the inner primary. But you also have to take off the outer primary,and remove the bolt that holds the starter gear onto the starter shaft.

You need to pull primary. Then remove starter gear bolt. Disconnect battery. Then remove 2 starter allen bolts. Disconnect battery off starter and start wire. MOPAR KENNY

take off negative cable off battery take cable off starter take 2 bolts off starter put new starter on the same way

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.

To remove your starter, first disconnect the negative side of your battery. Then drain the primary and remove the outer cover. Remove the small bolt that holds the starter jackshaft in and pull the jackshaft out of the seal. If the coupling comes out with it, make sure you mark the coupling which way it goes in. The tapered end goes in towards the starter.

Now, on the right side of the bike, remove the exhaust system or anything that might be in the way of removing the starter. There are two large bolts that hold the starter into the inner primary, remove these bolts and disconnect the battery cable and the small solenoid wire.

Good Luck
Steve

To remove the starter, first disconnect the battery. Then drain the primary and remove the outer primary cover. Take the bolt out of the starter jackshaft and remove it. If the coupler comes out with the jackshaft, make sure you mark which way it goes back in. The beveled ends goes towards the starter.

Now, on the other side of the bike, remove the exhaust system and anything else that might be in your way of getting to the starter. Remove the large battery cable from the starter. Take the two large 5/16" bolts out of the starter. The starter will lift out now.

Reinstalling the starter is the exact reverse of these directions.

Good Luck
Steve

Disconnect the battery first thing, negative wire first. The starter on your bike is a Nippondenso type starter. The solenoid and starter motor are built together as a single unit. The solenoid part of the starter is the top part that is shaped like a pentagon. The motor itself is below that part and is round.

You will have to remove the outer primary cover to remove the jack shaft, the little gear that turns the outer clutch drum. When you remove the starter, there is a splined coupling inside that goes in the starter in a particular direction. The end with the bevel goes towards the starter. Make sure you take notice of this and mark it if you can't remember which way it goes in.

Other than this, changing the starter is pretty straight forward.

Disconnect the battery, remove the outer primary cover. Remove the jackshaft bolt, lockwasher and seal. remove the battery box and battery. remove 2 starter bolts 1/4 allens, and remove the green wire terminal ( the 50 terminal ) .

I’m happy to assist further over the phone at https://www.6ya.com/expert/robert_5bac37c3cb991fdb

Yes... you need to remove the outer primary because thats the only way to get to the jack shaft.... remove the jack shaft and the u can unbolt the starter