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--- techtalk:ih:engctl03b [2020/04/30 21:46]
hippysmack [1977-1978 Kicker Cover Damage Repair]
+++ techtalk:ih:engctl03b [2023/12/10 07:00]
hippysmack [1977-1978 Kicker Cover Damage Repair]
@@ Line 3: / Line 3: @@
 ====== 1977-1978 Kicker Cover Damage Repair ======
-Article by Hopper of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=232588)) \\
+Article by Hopper of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/52379-sprocket-cover-kick-starter-damage-repair-kit)) \\
-This little bracket is the cure for broken sprocket covers and mountings on kickstart 1977 models. \\
+This little bracket is the cure for broken sprocket covers and mountings on kickstart 1977-1978 models. \\
-It can also be fitted to pre-1977 models with minor modifications to the sprocket cover. \\
 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. \\
 It basically bolts to the two rear engine mounting studs and sticks out around the kicker shaft so the cover can bolt to it. \\
 Mid-77 models have the extra bolt hole in the cover. \\
-Earlier models will need a patch welding inside the cover and drilling. Easy enough to do. \\
+Earlier 77 models will need a patch welding inside the cover and drilling. Easy enough to do. \\
-**Pics: The "spacer` as HD calls it**. \\
+**Pics: The "spacer" as HD calls it**. \\
 {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_1_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_2_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_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 34: @@
 {{: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 is 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 64: @@
 {{: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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