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techtalk:ih:engctl03b [2020/04/30 22:18] 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)) \\ |
| - | 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). \\ | ||
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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. \\ |
| - | **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_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 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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| 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. \\ | ||
| - | {{: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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| And here is the factory support bracket fix kit in place around the kick starter shaft. \\ | 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. \\ | 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. \\ | + | Third pic is of the top bracket before I drilled and tip it in position. \\ |
| Nice welding job by my aircraft welder buddy there. \\ | 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_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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| It is easier to just buy an aftermarket 1978 sprocket cover, it already has this in place. \\ | 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_16_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_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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| 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. | ||
| - | {{: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)) \\ |
| And I did have to grind a little clearance on the factory spacer to allow for the oversize 22-tooth sprocket. \\ | 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)) \\ | + | {{: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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| A rough sketch I made by laying the part on paper and drawing around it, then measuring up. \\ | 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)) \\ | + | {{: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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