INSTRUCTIONS - Harley
Contents
1. 2 Remove the existing starter according to the instruc tions found in the STARTER REMOVAL section of the Service Manual 3 For all except FLT Models Install the new starter according to the STARTER INSTALLATION instructions for the original equipment starter found in the Service Manual Proceed to Step 4 For FLT Models See Figure 1 When installing this starter on FLT model motorcycles remove the oil filler spout CAUTION Perform this installation when the engine is cool Working near the exhaust system when the engine is hot could result in minor or moderate injury To remove the oil filler spout on FLT Models i01872a 4 Breather hose 5 Hex socket screw 4 1 Oil filler cap dipstick 2 Oil filler spout 3 Gasket Figure 1 Remove Oil Filler Spout FLT Models Only a Place a drain pan under the engine oil pan b Remove the oil filler cap dipstick 1 and set aside NOTE Screws are difficult to reach but can be carefully removed without disconnecting the exhaust system c Leave the breather hose item 4 if so equipped to the oil filler spout 2 Remove the four hex socket screws 5 holding the spout to the transmission housing Remove the oil filler spout Wrap with a shop rag and set aside out of the way d Carefully scrape all gasket material from the transmission housing being sure not to cut into the gasket surface on the transmission housing e Install the new starter acc2. SMOTOR2 HARLEY DAVIDSON Uy J01624 INSTRUCTIONS REV 06 21 2002 Kit Number 31559 99 HIGH PERFORMANCE 1 4KW STARTER CHROME General This kit fits 1994 and later Big Twin Evolution and Twin Cam 88 engines See the Service Parts illustration for a list of items contained in this kit FLT Models will also require a new Oil Spout Gasket Part Number 62432 93A available separately WARNING A Service Manual is required to install this kit The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury NOTE A Service Manual for your model motorcycle is available from your Harley Davidson dealer Installation To protect against shock and accidental start up of vehicle disconnect the battery cables negative cable first before proceeding Inadequate safety precautions could result in death or serious injury Always disconnect the negative battery cable first If the positive battery cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion which could result in death or serious injury 1 Refer to the SEAT and BATTERY sections of the Service Manual Remove the seat and disconnect the battery cables negative cable first
3. dler 31525 90 Roller Idler 9077 Retainer Idler 31530 90 J01624 D 1 1 1 1 1 1 1 1 1 1 1 2 Description Ball Steel Spring Return Repair Kit Starter incl Plunger and Gasket Plunger Sub Assembly Solenoid Cover Kit Chrome includes Switch Gasket Gasket Switch Clutch Sub Assembly Starter incl Clutch Spring amp Shaft Clutch Starter Spring Shaft Output Housing Starter O Ring Bolt Starter w Washer 2 Nut w Washer not shown Part No 8879 31600 90 31604 91 31665 90 31783 00 31687 90 31516 94 31663 90 31692 90 31664 94 Not sold 11116 928 31694 90 2 of 2
4. ording to the STARTER INSTALLATION instructions for the original equipment starter found in the Service Manual f Place the new gasket 3 in position and re attach the oil filler spout Tighten the screws to 7 9 ft lbs 9 5 12 2 Nm g Re install the oil filler cap dipstick Check the oil level Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 4 Connect the battery cables positive cable first 5 Refer to the Service Manual and follow instructions to install the seat 1 of 2 Awarninc After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could result in shifting during vehicle operation loss of con trol of vehicle death or serious injury SMOTORZ e Service Parts Part No 31559 99 Date 06 02 High Performance 1 4KW Starter Chrome sp31559 99b Item Description 1 Bearing Ball 15mm I D 8871 Bearing Ball 8mm I D 8883 O Ring Yoke 2 31695 90 Holder Assembly Starter Brush includes Brush Springs 31518 90 Spring Starter Brush 4 31661 90 Drain Vent 31660 90 End Frame Starter Not sold Through Bolt Chrome 2 3624 Screw Chrome w O Ring 2 1036 Cap Terminal Rubber 31662 90 Nut Flange 3403 Washer 6217 Switch Assembly Not sold Gear I
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