How to remove starter from ultra classic. engine in frame with exhaust hooked up.engine still assembled. will the primary have to be removed. battery disconnected.

1. Remove seat.
To protect against accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.
2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.
3. Remove the primary chaincase cover.
4. Bend tab on lockplate away from head of jackshaft bolt.
5. Holding pinion gear to prevent rotation, remove the jackshaft bolt with lockplate and thrust washer.
6. From right side of motorcycle, remove starter front mounting screw with lockwasher. Remove rear mounting screw with lockwasher (and battery negative cable ring terminal). Remove Keps nut from stud of bracket tab and remove exhaust support bracket.
7. Pull back rubber boot and remove flange nut from starter post. Remove main power and battery positive cable ring terminals from starter post.
8. Depress external latch and pull solenoid connector from top of starter housing.
9. Locate oil filler plug/dipstick on right side of motorcycle at top of transmission case. To remove the oil filler plug, pull steadily while moving plug back and forth.
10. Remove the starter from the right side of the motorcycle, carefully sliding it through the space between the exhaust pipe and side cover.
NOTE: If necessary, remove Allen screw and decorative chrome
cover to facilitate starter removal.
11. Remove the coupling from the starter motor output shaft, if necessary.

If you are not mechanically adapt do not try this as it involves quite a lot of disassembly.
First, disconnect battery, negative side first.
1. Remove primary chaincase cover.
Bend tab on lockplate away from
head of jackshaft bolt. Hold pinion gear in place and
remove jackshaft bolt, lockplate and thrust washer.
4. Remove rear exhaust pipe.
5. Remove screw and end cover from starter.
6. Remove oil tank to provide clearance for starter removal.
7. Remove both starter mounting bolts and washers. This includes detaching the engine ground cable.
8. Remove protective boot over connector. Remove nut with washer (metric).
a. Remove positive battery cable ring terminal.
b. Remove circuit breaker wire ring terminal.
c. Detach solenoid wire.
9. Remove starter from right side of motorcycle.

Assembly is in reverse order. As you can see, quite a big job.

Pull MAXI fuse or disconnect battery.Drain primary, then remove primary cover, remove bolt from jack shaft on starter and pull of gear. On the other side remove the two 1/4 alan bolts holding starter on and of course remove starter wire.You will have to replace the seal after.

This removal requires some special tools and a manual. First remove the negative battery cable.Drain and remove primary cover. Remove the shift shaft from the housing.Remove the primary drive. The clutch nut has left-hand threads so righty loosey. Remove the small screw on the end of the starter gear shaft. Remove the screws holding the inner primary housing. Now on the right side. Remove the exhaust. Remove the two screws holding the starter motor to the trans housing. Inner primary will now come off. There is a race that is pressed onto the mainshaft that requires a special puller to remove. Drain trans fluid. Remove trans side cover, the one with the clutch cable. Remove the trans top cover. Remove the shifter drum. Remove the shift fork shaft through the right side of the trans bearing door. Remove the shift forks through the top off the trans housing noting location. Remove the screws that hold the bearing door to the case. There are a couple of pry points that you would use to separate the door from the case. Should come on out after all that.

To remove the starter, first, disconnect the negative cable from the battery. The drain and remove the outer primary. Remove the bolt that holds the jackshaft on and remove the jackshaft. If you can't get it out, you may have to remover the adjuster plate in the center of the clutch assembly. Loosen the nut and slide the clutch assembly off just slightly. The nut has LEFT HANDED threads in it.

Then, go to the right side of the bike and take off everything that is in the way of the starter, exhaust system, etc. Disconnect the battery cable from the starter and take the two large bolts out of the starter. The starter comes right out.

No, the engine does NOT have to come out of the frame.

First, disconnect the battery. Drain the primary cover, remove the shifter, foot peg, loosen the primary chain adjuster under the outer cover, whatever needs to be removed depending on your model Sportster to get the primary cover off.

From the right side of the bike, remove the exhaust system and whatever you need to remove to get the starter off. Disconnect the large battery cable and the single wire from the starter.

Back on the left side, there are two large bolts just above the clutch assembly, remove them. They may be different lengths so watch for that. Remove the starter.

Good Luck
Steve

To remove your starter, first disconnect the battery. Then remove the foot board on the left side of the bike. Drain the oil out of the primary and remove the outer primary cover. Take the small bolt out of the starter jackshaft and remove it.

Now, on the left side of the bike, you'll probably have to remove the exhaust system plus anything else that might be in the way of getting to the starter and the bolts that hold it on. Disconnect the battery cable at the screw post on the starter, 12 mm nut. There are two large bolts that hold the starter on that take an Allen wrench or hex key to remove. Take these two bolts out and the starter is loose. Work it out of the engine.

Good Luck
Steve

To remove the starter, first disconnect the battery. Then remove everything from the right side of the bike so that you can gain access to the starter.

Go to the left side of the bike and drain the primary and remove the cover. Remove the small bolt that holds the "starter jackshaft" on and remove the jackshaft.

Go back to the right side of the bike and disconnect the battery cable from the starter and the small wire from the starter relay. Remove the two large bolts that hold the starter on and remove the starter.

Good luck
Steve

On a Big Twin, you must pull the entire primary drive off the engine.

Disconnect the battery. Take the outer primary cover off the engine. Remove the compensator (engine sprocket) nut. This nut is very tight and has Loctite thread locker on it. 150-165 foot pounds of torque. You'll need to something to lock the chain up so the engine does not turn while loosening or tightening this nut. We use what is called a "locking bar". Remove the small plate with the screw and locknut in the center of the clutch assembly. Remove the mainshaft nut up inside the clutch assembly. It torques to 60-80 foot pounds LEFT HANDED TREADS. Remove the nut from the primary chain tensioner. Grab the compensator sprocket and the clutch assembly and lift the primary drive out of the cover.

Take the small screw out of the center of the jackshaft and remove the starter jackshaft.

From the right side of the bike, remove whatever you have to remove to get to the starter, exhaust pipes or whatever. Disconnect the battery cable and the small wire from the starter. Remove the two bolts holding the starter on inner primary cover.

Go back to the left side of the bike. Remove the four bolts that holds the inner primary to the engine, and the two that hold the primary to the transmission. There's one bolt coming in from the backside that has a braided wire on it on the early models. There may be four bolts holding the inner primary onto the transmission. When you have all the bolts out, the primary will come off easily. If it does not seem to want to come off, you may still have a bolt somewhere. Do not beat on the primary cover with even a rubber hammer. It should come right off.

Now, you'll have to remove the rear wheel, rear shocks, belt guards, and remove the swing arm.

As you can see, it's a pretty involved job on a Big Twin.

Good luck
Steve

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