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Type :
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starter
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Specification :
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12V 1.2KW
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Number of feet :
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9T
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Brand :
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nuojin
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Number :
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228000-2550
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Quality :
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Remanufacture
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Delivery time :
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10 day
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The installation process of the Harley-Davidson 12V 1.2KW starter motor aligns with the universal mounting logic for starter motors on this brand's motorcycles. Only the matching of corresponding specification bolts and wiring methods is required. Below is a detailed installation procedure tailored to Harley-Davidson model characteristics. Before operation, it is recommended to confirm the specific motorcycle model (e.g., Touring Series, Sportster Series), as slight variations in certain details may exist:
Prepare a 10mm wrench, 12mm wrench, 1/4-inch hex key wrench, torque wrench, blue thread locker, white grease or primary oil, clean rags, etc. Meanwhile, verify the new starter motor to ensure its 12V voltage and 1.2KW power are compatible with the motorcycle model. Check that the starter motor housing is free of cracks and the O-ring is intact.
Secure the motorcycle on a flat surface using the center stand. Remove the seat, and if equipped, the engine control module and protective cover(s) as well. Disconnect the negative battery cable with a 10mm wrench and keep it away from the battery terminal to avoid sparking, ensuring operational safety.
Apply white grease or primary oil to the O-ring at the end of the new starter motor. Insert the locating pin(s) into the corresponding holes on the starter motor; slightly expanding the locating pin(s) will enhance installation stability.
Carefully install the starter motor into the inner primary case. During installation, avoid squeezing the O-ring and prevent the locating pin(s) from falling out. Ensure the installation orientation of the starter motor matches that during removal to avoid component interference.
Apply one drop of blue thread locker to the threads of the starter motor mounting bolts. Insert the bolts into the mounting holes and hand-tighten them initially. Then use a torque wrench to tighten the bolts to the manufacturer's specified torque (torque values may vary by model, generally referencing 8-10N·m; refer to the vehicle manual for exact specifications).
Remove the rubber protective cover from the terminal on top of the starter motor. Use a 12mm wrench to attach the positive battery cable to the terminal and tighten the nut. Next, press the connector clip to connect the starter control wire to the starter solenoid, ensuring the clip is fully engaged to prevent loose connections.
Remove the rag from the engine oil filler neck, reinstall the oil filler cap and dipstick. Then sequentially reinstall the previously removed engine control module, protective cover(s), and seat. Finally, reconnect the negative battery cable and tighten it securely.
Turn on the ignition switch and press the start button to test. Under normal conditions, the starter motor should operate smoothly without harsh friction noises or jamming. If abnormalities occur, immediately turn off the power and inspect for potential issues such as loose wiring, misaligned locating pins, or a squeezed O-ring.
Throughout the entire installation process, the negative battery cable must be disconnected first. Ensure the cable is kept at least 5cm away from the battery terminal to avoid sparks caused by tools accidentally touching the positive and negative terminals. This requirement must be strictly followed, especially when operating near fuel lines, to prevent fire hazards.
The motorcycle must be fixed on a level, hard surface using the center stand. Operation with only the side stand is prohibited to avoid vehicle tipping during installation, which could result in personal injury or component damage.
When using tools such as wrenches and torque wrenches, ensure a stable grip to prevent slipping and damaging the engine or hands. Do not use damaged or deformed tools (e.g., stripped wrenches) to avoid bolt slipping during operation.
It is recommended to wear non-slip gloves and safety goggles to prevent hand slipping after contact with oil/grease, and to protect eyes from metal debris or oil splashes.
Before installation, reconfirm that the parameters of the new starter motor (12V voltage, 1.2KW power) are compatible with the original vehicle. Verify that the starter motor model, mounting holes, and locating pin dimensions match the original old part to avoid installation interference or functional failure due to mismatched models.
Check that the new starter motor housing is free of cracks and deformation, and that the solenoid terminals are free of oxidation and looseness.
Confirm the O-ring is intact, without aging or damage. If the O-ring is missing or damaged, replace it immediately (it is recommended to keep a spare O-ring of the same specification).
Rotate the starter motor gear shaft; it should move smoothly without jamming or abnormal noise, ensuring the internal coil and mechanical structure are normal.
After removing the old starter motor, wipe the engine-side mounting surface and bolt holes with a clean rag to remove oil, carbon deposits, or metal debris. This prevents impurities from affecting installation fit and causing the starter motor to vibrate during operation.
Do not strike or forcefully press the starter motor with tools such as hammers or screwdrivers, as this may damage internal coils, deform the gear shaft, or crack the housing. If jamming occurs during installation, check if the locating pins are aligned or if there are impurities on the mounting surface instead of forcing it into place.
The mounting bolts must be applied with blue medium-strength thread locker (red high-strength thread locker is prohibited as it will make subsequent maintenance difficult). Only 1-2 drops should be applied to the thread portion to avoid excessive leakage of the adhesive contaminating the internal parts of the starter motor or engine components.
The O-ring must be coated with white grease or primary oil; butter is not allowed (it melts easily at high temperatures and loses effectiveness). This ensures the O-ring fits smoothly during installation and prevents seal failure due to extrusion deformation.
A torque wrench must be used to tighten the mounting bolts to the manufacturer's specified torque (for conventional Harley-Davidson models, the reference torque is 8-10N·m; refer to the corresponding vehicle service manual for exact values). Do not tighten randomly by feel.
If installing with two bolts, tighten them symmetrically and evenly to avoid excessive force on one side, which may deform the starter motor housing and affect gear meshing accuracy.
References：
The precautions for installing the Harley-Davidson 12V 1.2KW starter motor are compiled by integrating Harley-Davidson model characteristics, universal starter motor installation specifications, and relevant industry common sense. They do not originate from a single fixed source, and some of the cited sources in the original text contain minor inaccuracies. Detailed explanations are as follows:
The core content aligns with the universal installation characteristics of Harley-Davidson motorcycle starter motors. For example, the operational requirements for components such as the primary case, locating pins, and O-rings during installation are consistent with the key operational logic outlined in the Harley-Davidson Road King series starter replacement guide on the It Still Runs website—including applying lubricating oil to protect the O-ring and careful assembly to avoid component interference. However, this content is not a direct copy of the original manual for any specific Harley-Davidson model; instead, it distills the common precautions for installing starter motors across all Harley-Davidson motorcycle series.
Content such as "power disconnection operation," "avoiding forceful installation," and "tightening bolts to the specified torque" are universal industry guidelines for automotive starter motor installation. For instance, starter replacement precautions published on platforms like Autohome and PCauto repeatedly emphasize key points such as disconnecting the negative battery cable before disassembly/installation, prohibiting striking the starter motor, and tightening bolts to the specified torque. These universal specifications have been integrated into the model-specific operational scenarios of Harley-Davidson motorcycles.
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