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High Performance 1.4Kw Starter (Black - Harley

1. Frame Starter Bolt w Washer 3 31689 90 Unpainted See Note 31519 90 Clutch Sub Assembly Starter Through Bolt Chrome 2 3624 incl Clutch Spring amp Shaft 31516 94 Screw Chrome w O Ring 2 1036 Clutch Starter 31663 90 Cap Terminal Rubber 31662 90 Spring 31692 90 Nut Flange 3403 Shaft Output 31664 94 Washer 6217 Housing Starter Switch Assembly Unpainted See Note 31510 90 Unpainted See Note 31538 98 O Ring 11116 Gear Idler 31525 90 Bolt Starter w Washer 2 928 Roller Idler 9077 Nut w Washer not shown 31694 90 Retainer Idler 31530 90 Note Paint unpainted parts with Harley Davidson Black Texture Aerosol touch up Part Number 98606BF J02527 2 of 2
2. 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 a Place a drain pan under the engine oil pan b Remove the oil filler cap dipstick 1 and set aside INSTRUCTIONS REV 06 25 2002 Kit Number 31335 03 HIGH PERFORMANCE 1 4KW STARTER BLACK 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 Only 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 accord
3. SMOTOR2 HARLEY DAVIDSON Uy J02527 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 2 Remove the existing starter according to the instruc tions found in the STARTER REMOVAL
4. ing 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 WARNING 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 1of2 Part No 31335 03 Date 06 02 SMOTOR o Service Parts sp31559 99b High Performance 1 4KW Starter Black Item Description i Description Part No 1 Bearing Ball 15mm I D Ball Steel 8879 2 Bearing Ball 8mm I D Spring Return 31600 90 3 O Ring Yoke 2 31695 90 Repair Kit Starter 4 Holder Assembly Starter Brush incl Plunger and Gasket 31604 91 includes Brush Springs 31518 90 Plunger Sub Assembly 31665 90 Spring Starter Brush 4 31661 90 Gasket Switch 31687 90 Drain Vent 31660 90 Solenoid Cover Black 31688 90 End

High Performance 1.4Kw Starter (Black - Harley

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