Harley Davidson Touring 2004 Service Manual sm05a
5
HOME
SPECIFICATIONS 5.1
STARTER
Item
Free (no load) speed 3000 rpm (min.) @ 11.5 V
Free (no load) current 90 amp (max.) @ 11.5V
Stall torque 8.0 ft-lbs (10.8 Nm) @ 2.4 V
Specification
SERVICE WEAR LIMITS
Item
Brush length minimum 0.433 11
Commutator diameter
minimum
IN. MM
1.141 29
TORQUE VALUES
Item
Thru-bolts 39-65
End cover mounting
bracket
End cover center screw 90-110
Battery cable terminal
bolts
Starter front and rear
mounting screws
Oil filler spout allen head
socket screws
Starter jackshaft bolt
Solenoid terminal nut 70-90
ft/in-lbs Nm
in-lbs
50-60
in-lbs
in-lbs
60-96
in-lbs
13-20 ft-lbs 18-27 Nm
84-108
in-lbs
60-80
in-lbs
in-lbs
4.4-7.3 Nm
5.6-6.8 Nm
10.2-12.4 Nm
6.8-10.9 Nm
9.5-12.2 Nm
6.8-9.0 Nm
7.9-10.2 Nm
2004 Touring: Starter 5-1
HOME
STARTER SYSTEM 5.2
GENERAL
The starter is made up of an armature, field winding assembly, solenoid, drive assembly, idler gear, and drive housing.
The starter motor torque is increased through gear reduction.
The gear reduction consists of the drive pinion on the armature, an idler gear, and a clutch gear in the drive housing. The
idler gear is supported by rollers and the clutch gear is part of
the overrunning clutch/drive assembly.
The overrunning clutch is the part which engages and drives
the clutch ring gear. It also prevents the starter from overrunning. The field windings are connected in series with the
armature through brushes and commutator segments.
The starter relay is a non-repairable part and must be
replaced if it malfunctions.
Operation (Figure 5-1)
When the starter switch is pushed, the starter relay is activated and battery current flows into the pull-in winding and
the hold-in winding, to ground.
The magnetic forces of the pull-in and hold-in windings in the
solenoid, pull the plunger and cause it to shift to the left, so
that the pinion gear is engaged with the clutch ring gear. At
the same time, the main solenoid contacts are closed and
battery current flows directly through the field windings to the
armature and to ground. Simultaneously, the pull-in winding
is opened.
The current continues flowing through the hold-in winding,
keeping the main solenoid contacts closed. At this point the
starter begins to crank the engine.
After the engine has started, the pinion gear turns freely on
the pinion shaft through the action of the overrunning clutch
which prevents the armature overrunning by the rotation of
the clutch ring gear.
When the starter switch is released, the current of the hold-in
winding is fed through the main solenoid contacts and the
direction of the current in the pull-in winding is reversed. The
solenoid plunger is returned to its original position by the
return spring, disengaging the pinion gear from the clutch
ring gear.
5-2 2004 Touring: Starter
HOME
Pinion
gear
Idler gear
STARTER AT MOMENT STARTER SWITCH IS CLOSED
Field winding
Plunger
Armature
Brush
Ball
bearing
Main
contacts
Clutch
ring gear
Pinion
gear
Overrunning
Idler gear
clutch
Field winding
Hold-In
winding
STARTER DURING CRANKING
Pull-In
winding
Start
circuit. See
wiring
diagram.
Battery
Armature
Brush
Ball
bearing
Plunger
Main
contacts
Clutch
ring gear
Overrunning
clutch
Figure 5-1. Starter Operation
Hold-in
winding
Pull-In
winding
Start circuit.
See wiring
diagram
Battery
2004 Touring: Starter 5-3
HOME
STARTER RELAY 5.3
REMOVAL
FLHR/C/S
FLHR/C/S
1. Remove left side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
block cover.
4. Pull fuse block from tabs on mounting panel. Tabs on
panel fit into slots on each side of fuse block cover.
NOTE
The fuse block cover also serves as the spare fuse holder.
One spare 10 amp and 15 amp fuse are provided.
5. Remove the fuse block cover. Raise lipped side slightly
to disengage slots from tabs on fuse block.
6. Pull relay from slots in fuse block. See upper frame of
Figure 5-2.
Brake Light
Relay [124]
Starter
Relay [123]
Check the wire tags for positive
identification of relays. Starter
relay can be positively identified
by heavy gauge Green wire.
NOTE
Starter
Relay [123]
f2210x8x
FLTR, FLHT/C/U
Ignition Keyswitch
Relay [126]
FLTR, FLHT/C/U
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
2. Locate the starter relay installed in cavity of frame crossmember at rear of battery box. See lower frame of Fig-
ure 5-2.
3. Place a finger on the rubber molding to hold it in position, and using a needle nose pliers, carefully pull on tab
to release starter relay. Since the position of the relays
may be reversed, starter relay can be positively identified by heavy gauge Green wire.
4. Remove harness connector from bottom of relay.
INSTALLATION
FLHR/C/S
1. Install
7. Slide cover over fuse block until slots fully engage tabs
8. Slide fuse block into position on mounting panel. Tabs on
new
relay in fuse block.
on block.
panel fit into slots on each side of fuse block cover.
f2192x8x
Figure 5-2. Locate Starter Relay
9. Slide maxi-fuse cover forward to engage tongue in
groove of fuse block cover and then insert maxi-fuse
holder into cover until latches engage.
10. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
5-4 2004 Touring: Starter
HOME
11. Install left side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
FLTR, FLHT/C/U
1. Install harness connector at bottom of
2. Place a finger on the molding to hold it in position and
push on relay until seated in cavity of frame crossmember.
3. Install seat. See Section 2.24 SEAT, INSTALLATION.
new
relay.
2004 Touring: Starter 5-5
Loading...