Harley Davidson 2008 Touring Models. Service Manual - page 38

 

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Harley Davidson 2008 Touring Models. Service Manual - page 38

 

 

3.

Capture front header pipe in exhaust bracket clamp. Use
a channel lock to close clamp, if necessary. Install carriage
bolt engaging transmission exhaust bracket and exhaust
bracket clamp. Finger tighten flange locknut.

4.

Slide a new TORCA clamp onto free end of front header
pipe.

5.

Install rear header pipe onto rear cylinder head and front
header pipe. Start flange nuts on cylinder head studs.
Move TORCA clamp into position between front and rear
header pipes.

6.

Slide new TORCA clamps onto free ends of rear header
pipe. TORCA clamp to crossover pipe is special in that it
has slot for bracket tab to exhaust support bracket.

7.

Slide right side muffler onto rear header pipe. Finger
tighten two screws (with lockwashers) to attach muffler to
lower saddlebag support rail. Place TORCA clamp into
position between rear header pipe and right side muffler.

8.

Moving to left side of motorcycle, install crossover pipe
onto remaining end of rear header pipe (above starter).
Place TORCA clamp into position between rear header
pipe and crossover pipe.

9.

Fit bracket tab into slot of TORCA clamp engaging stud
in slot of exhaust support bracket. Start Keps nut on stud.

10. Slide new TORCA clamp onto free end of crossover pipe.

11. Using a bungee cord, tie left side muffler to lower

saddlebag support rail. Install left side muffler on crossover
pipe. Place TORCA clamp into position between crossover
pipe and left side muffler. Finger tighten two screws (with
lockwashers) to attach muffler to saddlebag support rail.

NOTE

Verify that the exhaust pipes do not contact the motorcycle
frame or any mounted components. Contact will cancel the
effect of the rubber isolation mounts and transmit vibration to
the rider.

12. Tighten the exhaust system as follows:

a.

Tighten the top nut of the front cylinder head exhaust
flange to 9-18 in-lbs (1-2 Nm). Tighten the bottom
nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten
the top nut to 100-120 in-lbs (11.3-13.6 Nm).

b.

Tighten the bottom nut of the rear cylinder head
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
top nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten
the bottom nut to 100-120 in-lbs (11.3-13.6 Nm).

c.

Tighten flange locknut on exhaust bracket clamp
carriage bolt to 20-25 ft-lbs (27.1-33.9 Nm).

d.

Snug two screws (with lockwashers) holding the right
side muffler to the lower saddlebag support rail.
Alternately tighten screws to 96-144 in-lbs (10.8-16.3
Nm).

e.

Snug two screws (with lockwashers) holding the left
side muffler to the lower saddlebag support rail.
Alternately tighten screws to 96-144 in-lbs (10.8-16.3
Nm).

f.

Verify that all exhaust pipes are in alignment and do
not contact the motorcycle frame or mounted compon-
ents.

g.

Tighten the four TORCA clamps to 45-60 ft-lbs (61-
81 Nm) in the following order: crossover pipe to left
side muffler, rear header pipe to right side muffler,
front header pipe to rear header pipe, and rear header
pipe to crossover pipe.

13. Tighten Keps nut on stud of bracket tab to 12-15 ft-

lbs (16.3-20.3 Nm).

14. Open worm drive clamps and install six heat shields on

exhaust pipes as marked during removal. Position each
clamp so that screw is on the outboard side in the most
accessible position and then tighten to 20-40 in-lbs (2.3-
4.5 Nm).

15. Remove bungee cord from left side muffler.

16. Install O2 sensors in front and rear header pipes. See

4.14 OXYGEN SENSORS (O2)

.

17. On HDI models, connect cable to exhaust valve actuator

as follows:

a.

Install cable clip onto slotted flange at front of active
exhaust valve.

b.

Push cam rearward and install ball end of cable into
slot. Verify that cable is properly seated in channel of
active exhaust valve.

18. Insert two allen head socket screws (with lockwashers

and flat washers) through frame weldment into right side
front footboard brackets. For best results, approach from
left side of motorcycle using a 3/8 inch ball allen with
extension. Alternately tighten screws to 30-35 ft-lbs (41-
48 Nm).

19. On Ultra models, install fairing lowers. See 

2.34 LOWER

FAIRING AND ENGINE GUARD

.

20. Install saddlebags. See 

2.27 SADDLEBAGS

.

4-38  2008 Touring Service:  Fuel System

4.19

ACTIVE EXHAUST (HDI)

EXHAUST VALVE ACTUATOR

Removal

1.

Remove right side caddy. See 

8.6 ELECTRICAL CAD-

DIES

.

2.

Remove two T27 TORX screws (with flat washers) to
release active exhaust valve actuator from caddy.

Installation

1.

Install two T27 TORX screws (with flat washers) to fasten
active exhaust valve actuator to right side caddy. Altern-
ately tighten screws to 32-40 in-lbs (3.6-4.5 Nm).

2.

Install right side caddy. See 

8.6 ELECTRICAL CADDIES

.

EXHAUST VALVE ACTUATOR CABLE

Removal

1.

Remove exhaust valve actuator. See EXHAUST VALVE
ACTUATOR in this section.

2.

Remove cable as follows:

a.

Push on metal sleeve at end of cable housing to
release plastic insert from slot in cable guide.

b.

Release cable from groove at center of actuator wheel
and gently pull barrel end from hole.

Installation

1.

Install cable as follows:

a.

Gently push barrel end into hole in actuator wheel
until cable engages groove at center.

b.

Push on metal sleeve at end of cable housing to
engage plastic insert in slot of cable guide.

2.

Install exhaust valve actuator. See EXHAUST VALVE
ACTUATOR in this section.

ACTIVE EXHAUST VALVE

General

The active exhaust valve is not repairable. Replace the rear
exhaust header pipe if the valve is damaged or fails. See

4.18 EXHAUST SYSTEM

.

2008 Touring Service:  Fuel System  4-39

4.20

INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)

Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)

NOTES

•

To prevent false readings, keep air cleaner cover installed
when performing test.

•

Do not direct propane into air cleaner; false readings will
result.

•

Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backing plate. Even with air cleaner cover on, directing
nozzle too close to backing plate can give false readings.

LEAK TESTER

TOOL NAME

PART NUMBER

PROPANE ENRICHMENT KIT

HD-41417

Parts List

•

Standard 14 oz. propane cylinder.

•

PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly

1.

See 

Figure 4-43

. Make sure valve knob (6) is closed (fully

clockwise).

2.

Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment

1.

See 

Figure 4-43

. Press and hold trigger button (8).

2.

Slowly open valve knob (6) until pellet in flow gauge (7)
rises to between 5 and 10 SCFH on gauge.

3.

Release trigger button.

1

8

5

9

3

2

7

4

6

sm02629

1.

Propane bottle

2.

Nozzle

3.

Copper tube

4.

Hose

5.

Valve assembly

6.

Valve knob

7.

Flow gauge

8.

Trigger button

9.

Hanger

Figure 4-43. Leak Tester

PROCEDURE

1.

Start engine.

2.

Warm up engine to operating temperature.

NOTE

Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.

3.

See 

Figure 4-44

. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

4.

Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.

5.

When test is finished, close valve knob (turn knob fully
clockwise).

4-40  2008 Touring Service:  Fuel System

3

1

2

sm02630

1.

Propane bottle

2.

Trigger button

3.

Nozzle

Figure 4-44. Checking for Leaks

2008 Touring Service:  Fuel System  4-41

4.21

EVAPORATIVE EMISSIONS CONTROL (CA
MODELS)

GENERAL

Motorcycles sold in some markets are equipped with an
evaporative (EVAP) emissions control system. See 

Figure 4-45

.

The EVAP system functions as follows:

•

The fuel vapor vent tube connected to the vapor valve on
the fuel tank top plate allows fuel vapors in the fuel tank
to be vented to the charcoal canister. If the motorcycle is
tipped, the vapor valve also prevents the loss of gasoline
through the vent tube.

•

Under certain engine conditions, the ECM (working in
conjunction with the EFI system relay) opens the purge
solenoid. Negative pressure (vacuum) draws the fuel
vapors stored in the charcoal canister through the purge

tube to the induction module, where they are burned as
part of the normal combustion process.

Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)

NOTE

The EVAP system has been designed to operate with a min-
imum of maintenance. Check that all tubes are correctly routed
and properly connected. Also, verify that the tubes are not
pinched or kinked, and that there is no contact with the drive
belt and hot exhaust or engine parts.

1

2

6

7

8

4

5

3

sm04029

5.

1.

Purge tube (long)

Fuel tank top plate

2.

6.

Vapor valve

Purge solenoid

7.

3.

Purge tube (short)

Fuel vapor vent tube

4.

8.

Charcoal canister

Induction module

Figure 4-45. Evaporative Emissions Control System (EVAP)

4-42  2008 Touring Service:  Fuel System

VAPOR VALVE

NOTE

See 

Figure 4-46

. The vapor valve is not serviceable. Damage

or failure of the vapor valve requires replacement of the fuel
tank top plate. See 

4.5 FUEL TANK TOP PLATE

.

sm04094

Figure 4-46. Fuel Tank Top Plate With Vapor Valve

FUEL VAPOR VENT TUBE

Removal

1.

Remove fuel tank console as follows:

a.

Remove socket screw to release front of console from
fuel tank weldment.

b.

Remove hex screw to release rear console bracket
from clip nut on rear fuel tank bracket.

c.

Lay a clean shop towel on forward part of rear fender.

d.

FLHR/C: Remove console and lay upside down on
shop towel.

e.

FLHX, FLHT/C/U, FLTR: Press button to open fuel
door on console. Remove filler cap. Remove console
and lay upside down on shop towel. Install filler cap.

2.

Remove fuel vapor vent tube from fitting on vapor valve.

3.

Remove charcoal canister. See CHARCOAL CANISTER
in this section.

4.

Raise battery tray as necessary to release fuel vapor vent
tube from channel at bottom of battery tray.

5.

Carefully draw fuel vapor vent tube out through opening
on right side of motorcycle.

Installation

1.

Feed end of fuel vapor vent tube (opposite elbow fitting)
under battery tray to left side of motorcycle.

2.

From front left corner of battery tray, route fuel vapor vent
tube forward first following rear of frame crossmember
and then top of upper left frame tube to top plate.

3.

Install fuel vapor vent tube onto fitting of vapor valve.

4.

Install fuel vapor vent tube into channel at bottom of battery
tray (positioned below purge tube).

5.

Install charcoal canister. See CHARCOAL CANISTER in
this section.

6.

Install fuel tank console as follows:

a.

FLHR/C: Exercising caution to avoid pinching wire
harness and vent tube, position console on fuel tank.

b.

FLHX, FLHT/C/U, FLTR: Remove filler cap, if
installed. Exercising caution to avoid pinching wire
harness, fuel overflow hose and vent tube, position
console on fuel tank. Install filler cap.

c.

Start socket screw to fasten front of console to fuel
tank weldment.

d.

Start hex screw to fasten rear console bracket to clip
nut on rear fuel tank bracket.

e.

Alternately tighten socket/hex screws to 36-60 in-
lbs (4.1-6.8 Nm).

NOTE

In those markets where the charcoal canister, purge solenoid
and purge tube are absent, the fuel vapor vent tube is vented
to the atmosphere. Properly installed, it runs from the vapor
valve rearward along the inboard side of the upper left frame
tube, and then downward following the rear of the middle frame
downtube. The free end of the tube is then routed to the out-
board side of the frame weldment (holding the side cover
grommet) through the opening at the bottom. To avoid contact
with hot exhaust parts, the tube must hug the downtube at rear
of the swingarm bracket as shown in 

Figure 4-47

. If it does not,

disconnect tube at the rubber coupling, rotate as necessary
until the desired result is achieved, and then reconnect.

sm04299

Figure 4-47. Fuel Vapor Vent Tube Routing Absent EVAP

System

CHARCOAL CANISTER

Removal

1.

Remove saddlebags. See 

2.27 SADDLEBAGS

.

2.

Remove side covers.

3.

Remove battery. See 

1.16 BATTERY MAINTENANCE

.

4.

Remove spring clip and pull TSM/HFSM module out of
cavity in frame crossmember.

2008 Touring Service:  Fuel System  4-43

5.

Remove right side caddy, if present. See 

8.6 ELECTRICAL

CADDIES

.

NOTE

The right side caddy is only present on California motorcycles
equipped with ABS. If not provided, simply remove the socket
head screw and spacer to release support arm of battery tray
from frame weldment.

6.

Remove front socket head screw to release left side caddy
from battery tray.

7.

Note the three fingers at the front of the battery tray.
Remove socket head screw (with lifting strap) to release
middle finger from frame crossmember.

8.

Pull up on battery tray to release tab on left side caddy
from slot. See 

Figure 4-48

.

9.

Disconnect fuel vapor vent tube (vapor valve to charcoal
canister) from front fitting stamped "TANK."

10. Disconnect purge tube (charcoal canister to purge

solenoid) from rear fitting stamped "PURGE."

11. Remove two T25 TORX screws (with flat washers) to

release charcoal canister from bottom of battery tray.

12. Raise battery tray and slide charcoal canister out opening

on right side of motorcycle. See 

Figure 4-49

.

Installation

1.

Slide charcoal canister under battery tray using opening
on right side of motorcycle.

2.

Align holes in charcoal canister with those in battery tray
and start two T25 TORX screws (with flat washers).
Alternately tighten screws to 10-15 in-lbs (1.1-1.7 Nm).

3.

Connect purge tube (charcoal canister to purge solenoid)
to rear fitting stamped "PURGE."

4.

Connect fuel vapor vent tube (vapor valve to charcoal
canister) to front fitting stamped "TANK."

5.

Start socket head screw (with lifting strap) to fasten middle
finger of battery tray to frame crossmember.

6.

Push down on battery tray to engage tab on left side caddy
in slot.

7.

Start front socket head screw to fasten left side caddy to
battery tray.

8.

Alternately tighten two socket head screws to 72-96 in-
lbs (8.1-10.9 Nm).

sm04087

Figure 4-48. Disengage Left Side Caddy Tab From Battery

Tray Slot

sm04079

Figure 4-49. Charcoal Canister

9.

Verify that fuel vapor vent tube and purge tube are still
captured in channel at bottom of battery tray. See

Figure 4-50

. Also, to avoid possible contact with drive belt,

be sure that tubes are positioned inboard of tab at front
of left side caddy. See 

Figure 4-51

.

10. Check all routing to be sure that tubes are not pinched or

kinked, and that there is no contact with hot exhaust or
engine parts.

11. Install right side caddy, if present. See 

8.6 ELECTRICAL

CADDIES

.

NOTE

The right side caddy is only present on California motorcycles
equipped with ABS. If not provided, simply install the socket
head screw and spacer to fasten support arm of battery tray
to frame weldment. Tighten screw to 72-96 in-lbs (8.1-10.9
Nm).

4-44  2008 Touring Service:  Fuel System

sm04209

Figure 4-50. Capture Tubes in Channel of Battery Tray

2

3

1

sm04093

1.

Fuel vapor vent tube

2.

Purge tube

3.

Caddy tab

Figure 4-51. Move Tubes Inboard of Left Side Caddy Tab

12. Install TSM/HFSM module into cavity in frame cross-

member and install spring clip.

13. Install battery. See 

1.16 BATTERY MAINTENANCE

.

14. Install side covers.

15. Install saddlebags. See 

2.27 SADDLEBAGS

.

PURGE TUBE (LONG)

Removal

1.

Remove fuel tank. See 

4.4 FUEL TANK

.

2.

Remove purge tube from top fitting of purge solenoid.

3.

Pull two cable clips on purge tube from holes at bottom of
frame crossmember.

4.

Remove charcoal canister. See CHARCOAL CANISTER
in this section.

5.

Raise battery tray as necessary to release purge tube from
channel at bottom.

6.

Carefully draw purge tube out through opening on right
side of motorcycle.

Installation

1.

Feed end of purge tube (opposite elbow fitting) under
battery tray to left side of motorcycle.

2.

From front left corner of battery tray, route purge tube
forward first following front of frame crossmember and
then bottom of upper left frame tube to purge solenoid.

3.

Install purge tube onto top fitting of purge solenoid.

4.

Install two cable clips on purge tube into holes at bottom
of frame crossmember.

5.

Install purge tube into channel at bottom of battery tray
(positioned above fuel vapor vent tube).

6.

Install charcoal canister. See CHARCOAL CANISTER in
this section.

7.

Install fuel tank. See 

4.4 FUEL TANK

.

PURGE SOLENOID

Removal

1.

Remove fuel tank. See 

4.4 FUEL TANK

.

2.

Remove purge solenoid connector [95], 2-place Packard.

3.

Remove purge tube from charcoal canister from top fitting
of purge solenoid.

4.

Remove purge tube to induction module from bottom fitting
of purge solenoid.

5.

Insert a small flat blade screwdriver between purge
solenoid and bracket on left side of motorcycle. Rotate
screwdriver slightly to depress middle locking finger on
bracket and pull purge solenoid from motorcycle. See

Figure 4-52

 and 

Figure 4-53

.

sm04082

Figure 4-52. Depress Locking Finger to Release Purge

Solenoid

2008 Touring Service:  Fuel System  4-45

sm04083

Figure 4-53. Purge Solenoid

Installation

1.

Slide purge solenoid onto bracket on left side of motor-
cycle. If it does not lock into position, remove purge
solenoid and bend middle locking finger on bracket
downward slightly using a small flat blade screwdriver.
Reinstall purge solenoid.

2.

Install purge tube to induction module onto bottom fitting
of purge solenoid.

3.

Install purge tube from charcoal canister onto top fitting
of purge solenoid.

4.

Install purge solenoid connector [95], 2-place Packard.

5.

Check all routing to be sure that tube is not pinched or
kinked, and that there is no contact with hot exhaust or
engine parts.

6.

Install fuel tank. See 

4.4 FUEL TANK

.

PURGE TUBE (SHORT)

Removal

1.

Remove fuel tank. See 

4.4 FUEL TANK

.

2.

Remove purge tube from bottom fitting of purge solenoid.

3.

Remove purge tube from fitting at top of induction module.

Installation

1.

Install purge tube onto fitting at top of induction module.

2.

Install purge tube onto bottom fitting of purge solenoid.

3.

Check all routing to be sure that tubes are not pinched or
kinked, and that there is no contact with hot exhaust or
engine parts.

4.

Install fuel tank. See 

4.4 FUEL TANK

.

4-46  2008 Touring Service:  Fuel System

5.1

SPECIFICATIONS: STARTER

SPECIFICATIONS

Table 5-1. Starter Specifications

STARTER DATA

3000 RPM (min.) @ 11.5 V

Free speed

90 amp (max.) @ 11.5 V

Free current

200 amp (max.) @ 68°F

Cranking current

8.0 ft-lbs (10.8 Nm) @ 2.4 V

Stall torque

Table 5-2. Service Wear Limits Specifications

MM

IN.

SERVICE WEAR LIMITS

11.0

0.433

Brush length minimum

28.981

1.141

Commutator diameter minimum

2008 Touring Service:  Starter  5-1

1

2

3

4

5

6

8

7

9

10

11

12

11

13

16

17

18

19

15

23

22

21

20

26

25

24

31

32

30

42

41

40

39

38

37

36

35

34

33

29

28

27

29

14

sm05074

29.

15.

1.

O-ring (2)

Solenoid

Allen head screw

2.

30.

16.

Chrome end cover

Idler gear

Hex screw (3)

17.

3.

31.

Solenoid cover

Keps nut (2)

Steel cylinder (5)

32.

18.

4.

Bearing cage

Rubber gasket

End cover bracket

5.

33.

19.

Thru bolt (2)

Snap ring

Plunger

20.

6.

34.

Jam nut (2)

Phillips screw (2)

Cup

35.

21.

7.

Pinion gear

Wave washer (2)

End cap

8.

36.

22.

Drain vent

Short spring

O-ring (2)

23.

9.

37.

Round bushing (2)

Brush holder

Spring seat

38.

24.

10.

Starter clutch

Square bushing (2)

Brush spring

11.

39.

25.

O-ring (2)

Long spring

Contact plate (2)

26.

12.

40.

Post bolt (2)

Field coil

Drive shaft

41.

27.

13.

Steel ball

Hex screw (2)

Field wire hex nut

14.

42.

28.

Armature and bearing

Return spring

Drive housing

Figure 5-1. Starter Assembly

5-2  2008 Touring Service:  Starter

5.2

STARTER

GENERAL

The starter is made up of a field coil assembly, solenoid
assembly and drive assembly. The repair instructions contained
in this section are divided into three major service areas
accordingly.

NOTE

For troubleshooting and diagnostic information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.

Wiring Diagrams

The starting circuit wiring diagram contains information about
wiring configuration. For additional information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.

REMOVAL

1.

Remove seat. See 

2.26 SEAT

.

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

2.

Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.

3.

Remove starter front and rear mounting screws with cap-
tive washers.

4.

Remove Keps nut from stud of bracket tab and remove
exhaust support bracket.

5.

Pull back rubber boot and remove hex nut from battery
post. Remove battery positive and main power cable ring
terminals.

6.

Remove starter solenoid connector [128] at front of starter.

7.

Remove engine oil filler cap/dipstick. Cover fill spout with
clean shop cloth to keep out dirt and debris.

NOTE

To facilitate starter removal, if necessary, remove two worm
drive clamps to release heat shield from rear header pipe.

8.

Remove starter from motorcycle carefully sliding it out
through space between rear exhaust header pipe and side
cover. Exercise caution to avoid losing two ring dowels
loosely installed in the primary chaincase (or starter)
flange.

INSTALLATION

1.

Verify that two ring dowels are installed in the primary
chaincase (or starter) flange.

2.

Lubricate o-ring on starter and bore of primary chaincase
with light film of clean primary chaincase lubricant.

3.

Carefully slide starter in through space between rear
exhaust header pipe and side cover. With starter solenoid
connector at front, move starter into its installed position.

4.

Remove shop cloth over fill spout and install engine oil
filler cap/dipstick at top of transmission case.

5.

Install slot of exhaust support bracket onto stud of bracket
tab aligning other holes with those in starter flange. Start
Keps nut on stud.

6.

Engaging hole in exhaust support bracket, install starter
front mounting screw with captive washer. Install starter
rear mounting screw with captive washer.

7.

Alternately tighten starter front and rear mounting screws
to 25-27 ft-lbs (33.9-36.6 Nm).

8.

Tighten Keps nut on stud of bracket tab to 12-15 ft-
lbs (16.3-20.3 Nm).

9.

Install main power and battery positive cable ring terminals
onto battery post. Install hex nut and tighten to 70-90 in-
lbs (7.9-10.2 Nm). Pull down rubber boot over terminal
connections.

10. Install starter solenoid connector [128] at front of starter.

NOTE

If removed, install three worm drive clamps to secure heat
shield to rear header pipe. Tighten clamp screws to 20-40 in-
lbs (2.3-4.5 Nm).

11. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten bolt
to 60-96 in-lbs (6.8-10.9 Nm).

12. Install seat. See 

2.26 SEAT

.

TESTING

Armature

1.

Remove armature and brush holder from field coil. See

5.2 STARTER, Field Coil Assembly

.

2.

Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than  0.015
in. (0.38 mm) of runout should be replaced or machined
on a lathe. Commutators should be replaced when dia-
meter is less than  1.141 in. (29.98 mm).

3.

Check depth of mica on commutator. If undercut is less
than  0.008 in. (0.20 mm), use an undercutting machine
to undercut the mica to  1/32 in. (0.79 mm) deep. The slots
should then be cleaned to remove any dirt or copper dust.

NOTES

•

See 

Figure 5-2

. If an undercutting machine is not available,

undercutting can be done satisfactorily using a thin
hacksaw blade. After undercutting, lightly sand the arma-
ture with crocus cloth to remove any burrs.

•

Do not use sandpaper or emery cloth on commutator. The
abrasive grit may remain on commutator segments and
could cause excessive brush wear.

4.

See 

Figure 5-3

. Check for a SHORTED ARMATURE.

a.

Place armature on growler (1).

b.

Hold a thin steel strip (2) (hacksaw blade), against
the armature core and slowly turn armature.

c.

A shorted armature will cause the steel strip to vibrate
and be attracted to the core. Replace the armature if
shorted.

2008 Touring Service:  Starter  5-3

5.

See 

Figure 5-6

. Check for a GROUNDED ARMATURE

with an ohmmeter or continuity tester.

a.

Touch one probe to any commutator segment.

b.

Touch the other probe to the armature core.

c.

There should be no continuity (infinite ohms). If there
is continuity, the armature is grounded. Replace a
grounded armature.

6.

See 

Figure 5-5

. Check for an OPEN ARMATURE with an

ohmmeter or continuity tester.

a.

Check for continuity between all commutator seg-
ments.

b.

There should be continuity (0 ohms) at all test points.
If there is no continuity at any test point, then the
armature is open. Replace an open armature.

5

6

1

1

2

2

3

4

7

7

sm02320

1.

Segments

2.

Mica

3.

Incorrect (Mica must not be left with a thin edge next to segments)

4.

Correct (Mica must be cut away clean between segments)

5.

Starting groove in mica with 3 cornered file

6.

Undercutting mica with piece of hacksaw blade

7.

Commutator

Figure 5-2. Undercutting Mica Separators

5-4  2008 Touring Service:  Starter

1

2

sm02325

1.

Growler

2.

Thin steel strip (hacksaw blade)

Figure 5-3. Shorted Armature Test Using Growler

sm03710

Figure 5-4. Grounded Armature Test

sm03711

Figure 5-5. Armature Open Test

Brushes and Brush Holder

1.

Remove armature and brush holder from field coil. See

5.2 STARTER, Field Coil Assembly

.

2.

Measure the brush length. If any one of four brushes is
less than  0.433 in. (11 mm), replace the field coil and
brush holder assembly. No further testing is necessary.

3.

See 

Figure 5-6

. Check for a GROUNDED FIELD COIL

WINDING with an ohmmeter or continuity tester.

a.

Touch one probe to the field coil housing (frame).

b.

Touch the other probe to each of two brushes
attached to the field coil winding.

c.

There should be no continuity (infinite ohms). If there
is continuity at either brush, then the field coil winding
is grounded. Replace the field coil/brush holder
assembly if grounded.

4.

See 

Figure 5-7

. Check for an OPEN FIELD COIL

WINDING with an ohmmeter or continuity tester.

a.

Touch one probe to the field wire.

b.

Touch the other probe to each of the two brushes
attached to the field coil winding(s).

c.

There should be continuity (0 ohms). If there is no
continuity at either brush, then the field coil winding(s)
are open. Replace the field coil/brush holder assembly
if open.

5.

See 

Figure 5-8

. Test the BRUSH HOLDER INSULATION

with an ohmmeter or continuity tester.

a.

Touch one probe to the holder plate.

b.

Touch the other probe to each of the positive (insu-
lated) brush holders.

c.

There should be no continuity (infinite ohms). If there
is continuity at either brush holder, replace the field
coil/brush holder assembly.

d.

Touch one probe to the non-insulated brush holders
and the other probe to the holder plate. If any resist-
ance is measured, replace the field coil/brush holder
assembly.

sm03712

Figure 5-6. Grounded Field Test

2008 Touring Service:  Starter  5-5

sm03713

Figure 5-7. Open Field Test

1

2

sm02331

Figure 5-8. Brush Holder Insulation Test

FIELD COIL ASSEMBLY

Disassembly

1.

Remove allen head screw to release chrome end cover,
if equipped.

2.

Remove two Keps nuts to release end cover bracket from
thru bolts, if equipped.

3.

Pull up rubber boot and remove hex nut with captive
lockwasher to release field wire ring terminal from post on
solenoid housing.

4.

Using a 5/16 inch socket, loosen two thru bolts to release
field coil from solenoid housing.

5.

Pull field coil with end cap from solenoid housing.

6.

Remove armature from field coil. Separating end cap and
field coil flanges will facilitate removal.

7.

Placing field coil on wooden block to prevent damage, use
impact driver to remove two Phillips screws with captive
washers from end cap. Discard screws.

8.

Remove end cap from field coil.

9.

Locate the two brushes attached to the field coil winding.
Pushing on inboard side of one brush, grasp free end of
brush spring on outboard side with the hooked end of a
suitable pick. Raise end of brush spring only as far as
necessary to free brush from brush holder. Repeat step
to release second brush and then remove brush holder
from field coil.

Inspection

1.

For testing procedures, see 

5.2 STARTER, Testing

.

2.

Inspect two o-rings in field coil bore for cuts, tears or signs
of deterioration.

3.

Inspect armature roller bearings. Bearings must rotate
freely without drag or sticking. Replace the bearings if
pitted or grooved.

4.

Replace brush springs if bent or distorted.

Assembly

1.

Attach brush holder to field coil. Locate the two brushes
attached to the field coil winding. Catch free end of brush
spring with the hooked end of a suitable pick. Raise end
of brush spring only as far as necessary to install brush
into brush holder. Repeat step to install second brush.

2.

Retract all four brushes for armature installation. For good
results, obtain four paper clips. Bend free end of each
paper clip outward approximately 90°. Then, pushing on
inboard side of brush, insert straight end of paper clip
between outboard side of brush and inboard side of brush
spring. Properly installed, the paper clip contacts the
framework of the brush holder to keep spring pressure off
the brush. Repeat step on remaining three brushes as
shown in 

Figure 5-9

.

3.

Install armature in solenoid housing so that larger bearing
on splined end seats in counterbore. Lubricate armature
bearings with high temperature grease, such as LUBRI-
PLATE 110, before installation.

4.

Mate field coil and solenoid housings. For proper
assembly, a nub on the field coil housing flange must
engage the slot on solenoid housing flange closest to the
short (field wire) post on the solenoid housing.

5.

Carefully place brush holder over armature. If additional
clearance is needed, use a small flat blade screwdriver to
gently push back the brushes slightly.

6.

When the brush holder is centered over the armature,
remove four paper clips to release brush springs. Verify
that ends of brush springs make proper contact with brush
sides.

7.

Install end cap aligning holes in cap with those in brush
holder. Start two new Phillips screws with captive washers.
Alternately tighten Phillips screws until snug.

8.

Install thru bolts to fasten field coil to solenoid housing.
Using a 5/16 inch socket, alternately tighten thru bolts to
39-65 in-lbs (4.4-7.3 Nm).

9.

Attach field wire ring terminal to short post on solenoid
housing and install hex nut with captive lockwasher.
Tighten hex nut to 70-90 in-lbs (7.9-10.2 Nm). Cover field
wire ring terminal with rubber boot.

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