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| techtalk:ih:engctl03b [2020/04/30 21:46] – [1977-1978 Kicker Cover Damage Repair] hippysmack | techtalk:ih:engctl03b [2023/12/31 18:50] (current) – hippysmack |
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| ====== 1977-1978 Kicker Cover Damage Repair ====== | ====== 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)) \\ |
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| 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. \\ | 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). \\ | 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. \\ |
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| 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 would just take two pieces of flat steel strap and a piece of 3/4" water pipe, some drilling and some welding. \\ |
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| It basically bolts to the two rear engine mounting studs and sticks out around the kicker shaft so the cover can bolt to it. \\ | 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. \\ | 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. \\ |
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| **Pics: The "spacer` as HD calls it**. \\ | **Pics: The "spacer" as HD calls it**. \\ |
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| {{: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_1_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_2_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) \\ |
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| {{: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)) \\ | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_3_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_4_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) \\ |
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| **Installed on the bike**: \\ | **Installed on the bike**: \\ |
| The bracket itself seems good and solid. The tube is thick walled so will not flex. \\ | The bracket itself seems good and solid. The tube is thick walled so will not flex. \\ |
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| {{: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)) \\ | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_5_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_6_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) \\ |
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| **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. \\ |
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| | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_13_by_hopper.jpg?direct&300|}} ((photo 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/page2?t=232588&page=2)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_14_by_hopper.jpg?direct&300|}} ((photo 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/page2?t=232588&page=2)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_15_by_hopper.jpg?direct&300|}} ((photo 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/page2?t=232588&page=2)) \\ |
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| {{: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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| I shaped and had welded a piece of a 3/8" aluminium plate inside the sprocket cover. \\ | 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. \\ | 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. \\ | 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. \\ |
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| {{: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 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_9_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_16_by_hopper.jpg?direct&300|}} ((photo 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/page2?t=232588&page=2)) \\ |
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| 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. \\ | 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. \\ |
| As well as this, I had my gearbox casing welded up and redrilled the wrecked original dowel holes, but I reckon that with these two brackets, that step might be optional. | As well as this, I had my gearbox casing welded up and redrilled the wrecked original dowel holes, but I reckon that with these two brackets, that step might be optional. |
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| {{: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)) \\ | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_10_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_11_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_12_by_hopper.jpg?direct&300|}} ((photo 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?t=232588)) \\ |
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| | And I did have to grind a little clearance on the factory spacer to allow for the oversize 22-tooth sprocket. \\ |
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| | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_17_by_hopper.jpg?direct&300|}} ((photo 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/page2?t=232588&page=2)) \\ |
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| | **Dimensions of the spacer**: \\ |
| | A rough sketch I made by laying the part on paper and drawing around it, then measuring up. \\ |
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| | {{:techtalk:ih:engctl:1977-1978_kicker_cover_repair_7_by_hopper.jpg?direct&700|}} ((photo 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?t=232588)) \\ |
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