- All Balls Bearings and Components

Starter Motor & Jackshaft

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Note: The steps here show the installation procedure on a 1998 Harley-Davidson FLT motorcycle, you should have a service manual for your particular vehicle to get a better understanding of your particular setup and have factory recommended torque levels and specifications on hand.

Check out the Additional Service Information Resources [1] for more information on finding service information for your specific vehicle.


Thoroughly clean the vehicle to make the job easier and prevent contamination of the new components during installation.

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Get your High Performance Starter Motor and Jack Shaft kit from ALL BALLS RACING [2].

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Remove the contents of your ALL BALLS RACING starter motor kit.

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Remove the contents of your ALL BALLS RACING jack shaft kit.

Arrange the components in an organized manner for easy installation. Note: wait to do this until the old parts are removed and you are ready to begin installing the new components.

Starter Motor Replacement

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Remove the seat bolt.

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Remove the seat.

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Disconnect the ground lead from the battery.


Remove the floorboard, shift lever and passenger foot pegs.

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Remove the drain plug and allow the primary oil to drain completely.

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Remove the mounting bolts and the primary chain case cover.

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Bend the tab on the lock washer.

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Extend the pinion gear so it can be held by the clutch driven gear and loosen the jack shaft bolt. Wrap the pinion gear with a rag and hold it with pliers if needed to keep it from turning when the bolt is loosened.

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Remove the jack shaft bolt and washers.

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Remove the pinion gear and spring, and check for any damaged teeth on the starter driven gear on the clutch basket. Replace the components as necessary.

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Follow the manufacturers instructions and remove the clutch and primary chain as an assembly.

Note: On some models the clutch hub main shaft nut has reverse or left hand threads.

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Remove the coupling and the old jack shaft.

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Locate the starter motor on the right side of the machine.

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Pull back the rubber boot, remove the lock nut and free the starter motor cables.

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Disconnect the solenoid connector.

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Remove the 2 starter motor mounting bolts. Some models may require the removal of an exhaust bracket.

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Remove the starter motor.

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Drive out the old jack shaft oil seal and note the direction of the seal for installation.

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Apply a thin coat of grease to the new oil seal lips.

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Install the new jack shaft oil seal into the left case half until it is fully seated.

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Note the direction and order of your new jack shaft and parts.

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Install the the splined washer onto the new starter motor, a small dab of grease will help hold it in place. Apply a thin coat of grease to the starter motor splines.

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Install the new starter motor onto the engine. Tighten the bolts to specification with a toque wrench.

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Using a suitable holding tool, carefully place the spring onto the starter motor shaft. Avoid damaging the oil seal or dropping the spring.

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Install the new jack shaft onto the starter motor shaft, carefully guide it through the oil seal. Make sure it fits correctly- you will feel it press against the spring.

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Install the clutch and primary assembly, follow the manufacturers instructions for proper reassembly.

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Install the plain washer onto the jack shaft bolt.

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Apply non-permanent thread locking agent to the bolt threads.

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Install the bolt into the jack shaft, hold the jack shaft with a suitable tool and tighten the bolt to 5 ft. lbs.

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Install the primary cover and fill with oil following the manufacturers instructions.


Install the floorboard, shift lever and passenger foot pegs following the manufacturer’s instructions.

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Connect the solenoid lead and battery cables, pull the rubber boot over the cables.

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Connect the negative battery lead.

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Install the seat and tighten the bolt securely to the manufacturers specification.




URLs in this post:

[1] Additional Service Information Resources: http://www.cyclepedia.com/manuals/online/cpp-all-balls/additional-service-information/

[2] ALL BALLS RACING: http://www.allballsracing.com/

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