Big Dog
How do you remove the starter on a 2001 Big Dog Husky motorcycle?
How do you remove the starter on a 2001 Big Dog Husky motorcycle? It has a 107 S & S engine.
If you don’t know how to do this….let a shop do it!!! It REQUIRES air tools and HIGH TORQUE values.
You must remove the outer primary cover and then remove the clutch assembly and compensator assembly to gain access to the starter jackshaft. Before doing this, you will want to check out the compensator spring pack assembly, during the early-mid 2000′s, these assemblies were known for weakening and needed to be replaced. To check it, before removal, lift the rear wheel and put the bike in 5th gear. Using the rear wheel to “rock” the engine back and forth, you look at the compensator and alternator rotor, while rocking the engine, if you see the rotor turning BEFORE the compensator, the compensator is bad and needs replaced.
On to the starter again, after the clutch and compensator assemblies are removed, unbolt and remove the jackshaft. Then the two 1/4″ allen bolts that hold the starter to the inner primary must be removed from the exhaust side, sometimes oil tnak removal is neccessary to gain access to these bolts. Once they are removed, undo the wiring to the starter, swap it out, and put it back together.
Take note…to remove the compensator nut and clutch hub nut, you will need an impact gun with a 1 1/2″ socket for the compensator and 1 1/8″ socket (if I remember correctly) for the clutch hub nut (REVERSE THREAD). When reassambling these, ALL threads MUST be COMPLETELY oil free by cleaning with brake cleaner. RED loctite must be used and these nuts must be torqued….comp nut 175 ft/lbs, clutch nut 100 ft/lbs. The clutch must be fully readjusted at the pushrod and cable (LUBE THE CABLE BEFORE REASSAMBLY)
Like I said, if you have to ask this, you are better off letting a pro do it. A pro can do this in less than 2 hours, it will take an average person at home all day to do this, and the average person does not have the tools or specs to do it.
Big Dog