Softail Starter Removal - Harley Forum

03fxst · #1 03-20-2009, 02:51 PM

The ring gear is fine, looks like my problem is in the starter. Probably the clutch. Parts guy tells me they fail so often he keeps three in stock at all times. So I guess I pull apart the starter.
The shop manual says the oil tank must come out to remove the starter. Service guy at the shop says that isn't true, just remove the battery, loosen the tank and the starter will come out. I know when I did the top end re-build the manual had me doing things that were not entirely necessary. Anyone with hands on experience on pulling out the starter.

Thanks
03FXST

evoKENevo · #2 03-20-2009, 03:37 PM

Yeah,03...your service guy is right...no need to remove the oil tank completely. I had to replace my starter clutch a couple years ago...and just loosened up the tank enough to get it out of the way. Only difference I can think of is that my EVO softail has flexible oil lines...and your TC probabley has the solid ones that'd have to be disconnected.

03fxst · #3 03-20-2009, 03:51 PM

Thanks Evo
Yep, mine are solid so I'll have to get that Oil Line removal tool and pop them off. Ooops, just called the dealer. It is a specialty tool with no retail listed. They tell me to expect one hundred dollars by the time it gets here. It is a tiny plastic tool that keeps the retainer inside the tank when the oil line comes out. Has anyone used anything else to do that?

03FXST

evoKENevo · #4 03-20-2009, 04:20 PM

Oh,hey...almost forgot that without removing the oil tank you're not going to have much room to use a regular old allen-wrench on the starter bolts...and maybe be needing an allen headed socket on a pretty long extention and maybe a u-joint.

Ooops...some how I missed your last post regarding the "special tool" and cost etc (note editing here) but "hey"read on...HC to the rescue,on something I could'nt help with anyhow

bless his "cobbling

soul" !!!

HarleyCruiser · #5 03-20-2009, 06:24 PM

Yea made one out of a piece of round plastic that was laying around the shop. Cut it half actually in thirds and slipped two around the pipe and pushed them in, worked.
Want a photo?
And they can't understand why we love to hate the company that makes the bikes we love.

Quote:

Originally Posted by 03fxst

Thanks Evo
Ooops, just called the dealer. It is a specialty tool with no retail listed. They tell me to expect one hundred dollars by the time it gets here. It is a tiny plastic tool that keeps the retainer inside the tank when the oil line comes out. Has anyone used anything else to do that?
03FXST

HarleyCruiser · #6 03-20-2009, 06:52 PM

Nope can’t find them, must have put them in that special place so I could find them in the future.
Measure the OD of the line then go to ACE and get a neoprene busing, with a ID the same. Don’t remember how thick,. but you can always file them thinner, so......
and an inch or so long.
I don’t remember if they had a flange on them like a axle bearing for a grill or something like that.
Then cut it in half then grind them so that they are about a quarter inch wide, maybe wider and push them in where you see the clip.
I think I did one at a time, mine fit so tight that they stayed in to push the other.
But you need to catch both before the line will come out.
Don’t remember if I pushed them in with a screwdriver or what.
Been a while.
I did not have to force them, they just went in and the clip moved out, and you pull the line out.

03fxst · #7 03-21-2009, 08:59 AM

Thanks HC
Okay, I think I'm seeing what you are saying. Essentially I am making a thin plastic shroud for the line that will slide into the hole on the tank and free the line from some type of clip that I gather is spring loaded. Does the line just slide back in without the tool when I put it all back together. I won't get at it today but should be able to get to the hardware store for the plastic tubing. I don't think I ever made a tool before.

03FXST

shovelmike · #8 03-21-2009, 11:29 AM

Hi there 03, good to see you. Best of luck to you with the project, let us know how it goes. It will be great if your home made tool made for pocket change does the job of H-D's $100 + tool.

HarleyCruiser · #9 03-21-2009, 12:16 PM

Yea the clip is that black thing, and you can see two tangs that grab the line, you are spreading them away from the line, as you push the tools in.
The tool goes between the line and the black thing.
the tool should slip in there and have a little resistance but if there is too much then the tool is too thick.
It will go in so far then just stop. Do both sides of the line, clip.
Don’t remember if I needed the tools to put them back in, but think they just pop in like a quick connection.
I am pretty sure there is a o-ring in there that seals the line.
Been a while.
And when working on Harleys You will have make a few tools.

Quote:

Originally Posted by 03fxst

Thanks HC
Okay, I think I'm seeing what you are saying. Essentially I am making a thin plastic shroud for the line that will slide into the hole on the tank and free the line from some type of clip that I gather is spring loaded. Does the line just slide back in without the tool when I put it all back together. I won't get at it today but should be able to get to the hardware store for the plastic tubing. I don't think I ever made a tool before.

03FXST

HarleyCruiser · #10 03-21-2009, 12:54 PM

Here this is a quick chicken scratch of what I am talking about.
What you want to buy, I think they call them flanged axle bearings, they are plastic.
The pipe, tube is about half inch ID and an inch so long, you can stick something in the clip to measure how long it has to be, like a feeler gauge.
Then cut on the dotted line.
And like I said I dont think my tool that I made had the flange, just the tube, and I used screw dirvers to push them in.

here is a store bought tool, but the photo is not very good. This is about the same thing but the two pieces are joined so that they hinge to open to go around the line.
Maybe try to follow the link back to there store, and maybe have a better picture, or do a search for oil line removal tool harley on the web.
TRANSMISSION, RADIATOR,ENGINE OIL COOLER LINE REMOVER - eBay (item 370073767835 end time Mar-28-09 11:18:58 PDT)