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--- techtalk:ih:engctl03b [2020/04/30 21:46]
hippysmack [1977-1978 Kicker Cover Damage Repair]
+++ techtalk:ih:engctl03b [2020/04/30 22:18]
hippysmack
@@ Line 9: / Line 9: @@
 It is standard equipment on 1978 kickstart models and was issued by HD as a retro fix kit for early 1977s. \\
 HD OEM part number for the spacer is (34848-77). \\
+It's in the -78A and -78B Parts Catalog in the transmission sections under part# (34850-77) - SPROCKET COVER KIT. \\
+But the part number for the spacer is shown in the -78B catalog. \\
-But they are not easy to find, so making one is a real option. \\
+They are not easy to find, so making the spacer is a real option. \\
 It would just take two pieces of flat steel strap and a piece of 3/4" water pipe, some drilling and some welding. \\
@@ Line 22: / Line 24: @@
 {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_3_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_4_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
+\\
 **Installed on the bike**: \\
@@ Line 31: / Line 35: @@
 {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_5_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_6_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
+\\
-**Dimensions of the spacer**: \\
+And here is the factory support bracket fix kit in place around the kick starter shaft. \\
-A rough sketch I made by laying the part on paper and drawing around it, then measuring up. \\
+Also my extra support bracket on top of the gearbox casing, ready to bolt the sprocket on when it arrives and then the cover. \\
+Third pic I of the top bracket before I drilled and tip it in position. \\
+Nice welding job by my aircraft welder buddy there. \\
+{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_13_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_14_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_15_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) \\
-{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_7_by_hopper.jpg?direct&700|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
 \\
 I shaped and had welded a piece of a 3/8" aluminium plate inside the sprocket cover. \\
 And then drilled a hole for the spacer bracket mounting bolt to go through. \\
 Covers before mid-77 will need this attachment point. Aftermarket covers for 77-78 will have this standard. \\
+Third, pic: the modified sprocket cover, welded, filed down and drilled to suit the factory support bracket spacer. \\
+It is easier to just buy an aftermarket 1978 sprocket cover, it already has this in place. \\
-{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_8_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_9_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
+{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_8_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_9_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_16_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) \\
+\\
 Then I made a big extra angle bracket to go from the bolt holes on top of the gearbox, over to support the top bolt on the sprocket cover. \\
@@ Line 54: / Line 65: @@
 {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_10_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_11_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_12_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
+And I did have to grind a little clearance on the factory spacer to allow for the oversize 22-tooth sprocket. \\
+{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_17_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) \\
+\\
+**Dimensions of the spacer**: \\
+A rough sketch I made by laying the part on paper and drawing around it, then measuring up. \\
+{{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_7_by_hopper.jpg?direct&700|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588)) \\
+\\

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