Replacing the starter motor on a 2002 Harley-Davidson Dyna Super Glide involves several steps. Please keep in mind that working on a motorcycle's electrical system requires caution and, if you're unsure, it's always advisable to consult a professional or refer to the motorcycle's service manual for detailed instructions. Here's a general overview of the process:
Gather the necessary tools and equipment: You'll typically need a socket set, wrenches, pliers, screwdrivers, and possibly a torque wrench. Ensure you have the correct replacement starter motor for your motorcycle model.
Disconnect the battery: Before beginning any work, disconnect the negative battery cable to prevent any accidental electrical contact.
Locate the starter motor: The starter motor is usually located on the bottom left side of the engine, near the primary drive housing. It is connected to the primary drive via a starter jackshaft.
Remove the primary drive cover: The primary drive cover protects the primary drive components. You'll need to remove it to access the starter motor. Depending on your specific model, there may be a few screws or bolts securing the cover.
Disconnect the starter motor: Locate the starter motor connections. There should be a positive cable and a smaller control wire. Carefully disconnect these wires, taking note of their positions for reinstallation.
Remove the starter motor: Using the appropriate tools, remove the bolts securing the starter motor to the primary drive housing. Take care not to drop any bolts into the primary drive or damage the surrounding components. Gently remove the starter motor from its mounting position.
Install the new starter motor: Position the new starter motor in place and secure it with the bolts. Tighten the bolts to the recommended torque specifications specified in the service manual.
Reconnect the starter motor: Reconnect the positive cable and control wire to the new starter motor, ensuring proper connections.
Reinstall the primary drive cover: Put the primary drive cover back in place and secure it with the screws or bolts you removed earlier.
Reconnect the battery: Finally, reconnect the negative battery cable.
Once you have completed these steps, you can test the starter motor to ensure it functions properly. Turn the ignition key and listen for the starter motor engaging and starting the engine. If everything is working correctly, you should be good to go.
Remember, this is a general overview, and the specific steps and procedures may vary for different motorcycle models. Always consult your motorcycle's service manual or seek professional assistance if you're unsure about any step in the process.