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--- techtalk:ih:engctl03b [2020/04/30 20:33]
hippysmack [1970-1978 Kicker Cover Damage Repair]
+++ techtalk:ih:engctl03b [2023/12/31 18:50] (current)
hippysmack
@@ Line 3: / Line 3: @@
 ====== 1977-1978 Kicker Cover Damage Repair ======
+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 1977-1978 models. \\
+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. \\
+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 77 models will need a patch welding inside the cover and drilling. Easy enough to do. \\
+**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 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)) \\
+{{: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)) \\
+\\
+**Installed on the bike**: \\
+Note the 1/4" bolt, pointed to, goes through the sprocket cover. \\
+Nuts are yet to be put back on the rear engine mount bolts. \\
+Looking straight down from on top, there is a divot ground in the tube where the rubber oil supply line will go. \\
+The bracket itself seems good and solid. The tube is thick walled so will not flex. \\
+{{: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)) \\
+\\
+And here is the factory support bracket fix kit in place around the kick starter shaft. \\
+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 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)) \\
+\\
+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 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)) \\
+\\
+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. \\
+(which I enlarged to 5/16" to make it stronger) \\
+Make sure it has the bit sticking out at the top so the angle does not hit the chain. \\
+I also had to make an extended gearbox breather fitting to allow for the bracket being fitted underneath it. \\
+It is just a bolt with a hole drilled in it and an old piece of metal brake line silver soldered in. \\
+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.
+{{: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)) \\
+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 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)) \\
+\\
+**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 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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