Zodiac ZPN 741203 Manual Del Usuario

. .
WWW ZODIAC NL
figure 1
figure 2
figure 3
figure 4
figure 5
figure 6
figure 7
ALL BALLS INSTALLATION INSTRUCTIONS
ZPN 741203 - 741204 - 741205 - 741206
Removal of the old starter
1. Remove the battery negative cable
2. Remove the cable from the starter. Note: You may need to remove the rear exhaust pipe
in order to gain access to the starter
3. Remove the two bolts on the back of the starter
4. Remove the starter from the motorcycle
a. Note 1: We strongly recommend replacing old battery cables if they are #6 wire or
are in poor condition. If your existing battery cables are #4 and are in good
condition, we recommend that you clean all the terminals well. A starter can only
produce it's rated output if enough current is coming into it. Bad cables or too small
a cable will result in poor starter performance
b. Note 2: Inspect your starter solenoid. If it is old or in poor condition, we
recommend either replacing it or rebuilding it
Installation of All Balls High Torque Starter
1. Remove the drive end housing from the starter
2. Remove the two thru bolts from the starter, See figure 1
3. Hold the drive-end housing and gently tap on the gear, See figure 2
a. Caution: Handle the motor portion carefully so that the armature does not fall out of
the starter, See figure 3
4. Once the drive-end housing has been removed from the starter, bolt the drive-end housing
onto the primary housing with the two socket cap screws supplied. Torque these two
socket cap screws to 45-60 inch pounds, See figure 4
5. Take the starter and place it into the drive-end housing, See figure 5
a. Note: The motorcycle should be in a warm garage for this operation. If the
motorcycle is in a cold environment, it will be difficult to slip the starter into the
drive-end due to a tight bearing bore fit at low temperatures.
6. Install the two thru-bolts and torque them to 50-65 inch pounds, See figure 6
7. Attach the cable to the starter post, See figure 7
8. Reattach the exhaust pipe and or other parts that had to be removed form the motorcycle
to access the starter
9. Reattach the ground cable to the battery
Removal of All Balls High-Torque Starter
1. Remove the battery negative cable
2. Remove the two thru-bolts
3. Pull the motor form the drive-end housing by pulling and wiggling the starter out of the
drive-end housing
a. Note: The starter armature may stay in the drive-end housing. If this occurs, you
will need to pull the armature out of the drive-end housing and reload it into the
motor
Installing the armature back into the Motor
1. Remove the tow small phillip screws in the rear starter casting
2. Remove the rear starter casting
3. Place the armature into the motor and work the four brushes onto the armature commutator
4. Reassemble the motor
PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ®
8-09-2005