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techtalk:ih:engmech01f [2023/12/17 21:31] hippysmack [1977-1978 XL/XLCH Inner Sprocket Cover] |
techtalk:ih:engmech01f [2024/01/02 03:44] (current) hippysmack [Ironhead Transmission Sprocket Cover Pics] |
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| ====== IH: Engine Mechanicals - Sub-01F ====== | ====== IH: Engine Mechanicals - Sub-01F ====== | ||
| ====== Ironhead Transmission Sprocket Cover Pics ====== | ====== Ironhead Transmission Sprocket Cover Pics ====== | ||
| + | See also in the Sportsterpedia; \\ | ||
| + | * . . . [[techtalk:ih:engctl03a|1968 Kicker Cover Roll Pin Repair]] \\ | ||
| + | * . . . [[techtalk:ih:engctl03b|1977-1978 Kicker Cover Damage Repair]] \\ | ||
| + | * . . . [[techtalk:ih:transfinal02a|How to Adjust a Dry Clutch]] \\ | ||
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| The stop pin (roll pin) is in the cover (underside). Look closely at these as they have a tendency to shear off flush with the cover. \\ | The stop pin (roll pin) is in the cover (underside). Look closely at these as they have a tendency to shear off flush with the cover. \\ | ||
| 1952-1956 covers do not have a gear stop pin. \\ | 1952-1956 covers do not have a gear stop pin. \\ | ||
| - | 1957-1967 covers were drilled through at the roll pin and you could drive it out from the outside. ((brucstoudt of the XLFORUM http://xlforum.net/forums/showthread.php?t=2061986)) \\ | + | 1957-1967 covers were drilled through at the roll pin and you could drive it out from the outside. ((brucstoudt of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/192529-kicker-cover-roll-pin?t=2061986)) \\ |
| 1968-1970 covers have a boss added to the underside in a wider girth around the worm gear. \\ | 1968-1970 covers have a boss added to the underside in a wider girth around the worm gear. \\ | ||
| The hole for the roll pin is drilled from the underside, through the boss, but not all the way through to the outside of the cover. \\ | The hole for the roll pin is drilled from the underside, through the boss, but not all the way through to the outside of the cover. \\ | ||
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| There were 2 types of grease (zerk) fittings used on 1952-1970 sprocket covers. \\ | There were 2 types of grease (zerk) fittings used on 1952-1970 sprocket covers. \\ | ||
| The threaded fitting is HD part# ( 9851) and it has 5/16"-32 UNEF threads and a straight shank. It only has 1 (maybe 2) useable threads. \\ | The threaded fitting is HD part# ( 9851) and it has 5/16"-32 UNEF threads and a straight shank. It only has 1 (maybe 2) useable threads. \\ | ||
| - | A lot of ripped out fittings comes from levering a too tightly fitting gun socket off the nipple (rips the fitting from the thread). ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1671259)) \\ | + | A lot of ripped out fittings comes from levering a too tightly fitting gun socket off the nipple (rips the fitting from the thread). ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156030-grease-fitting-size?t=1671259)) \\ |
| Most gun sockets are adjustable (loosen the business end of the socket from its mate). \\ | Most gun sockets are adjustable (loosen the business end of the socket from its mate). \\ | ||
| - | You can use an aftermarket grease fitting with longer threads as long as you measure to make sure there is enough room for it. ((The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1671259)) \\ | + | You can use an aftermarket grease fitting with longer threads as long as you measure to make sure there is enough room for it. ((The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156030-grease-fitting-size?t=1671259)) \\ |
| The fitting below is a Facca (H1631) straight grease fitting that was slightly shortened with a file. \\ | The fitting below is a Facca (H1631) straight grease fitting that was slightly shortened with a file. \\ | ||
| The extra length/thread on the shank doesn't strip out under pressure from your grease gun. \\ | The extra length/thread on the shank doesn't strip out under pressure from your grease gun. \\ | ||
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| The bushing is pressed in and is held there by tension in the bore and doesn't need to be held in. \\ | The bushing is pressed in and is held there by tension in the bore and doesn't need to be held in. \\ | ||
| - | {{:techtalk:ih:engmech:1957-1970_sportster_sprocket_cover_grease_fitting_alternative_by_the_doctor71.jpg?direct&400|}} ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1671259)) \\ | + | {{:techtalk:ih:engmech:1957-1970_sportster_sprocket_cover_grease_fitting_alternative_by_the_doctor71.jpg?direct&400|}} ((photo by The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156030-grease-fitting-size?t=1671259)) \\ |
| ====== Kick Starter Spring Stud ====== | ====== Kick Starter Spring Stud ====== | ||
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| {{:techtalk:ih:engmech:1952-1970_k_model_sportster_kick_spring_stud_33088-52_by_wheatstateparts.jpg?direct&400|}} ((photos courtesy of Ebay seller, WheatStateParts. [[https://www.ebay.com/str/cos0608|Link to Ebay Store]] )) {{:techtalk:ih:engmech:1952-1970_k_model_sportster_kick_spring_stud_33088-52_by_ebay_sum-body1.jpg?direct&400|}} ((photo courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\ | {{:techtalk:ih:engmech:1952-1970_k_model_sportster_kick_spring_stud_33088-52_by_wheatstateparts.jpg?direct&400|}} ((photos courtesy of Ebay seller, WheatStateParts. [[https://www.ebay.com/str/cos0608|Link to Ebay Store]] )) {{:techtalk:ih:engmech:1952-1970_k_model_sportster_kick_spring_stud_33088-52_by_ebay_sum-body1.jpg?direct&400|}} ((photo courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\ | ||
| - | The 1971-1979 stud was lengthened from the earlier version. The area between the spring retention groove and hex is longer. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=6013666#post6013666)) \\ | + | The 1971-1979 stud was lengthened from the earlier version. The area between the spring retention groove and hex is longer. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205696-ironhead-sprocket-covers#post4662020)) \\ |
| {{:techtalk:ih:engmech:1971-1978_kick_starter_spring_stud_33088-71_by_sum-body1.jpg?direct&400|}} ((photo courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\ | {{:techtalk:ih:engmech:1971-1978_kick_starter_spring_stud_33088-71_by_sum-body1.jpg?direct&400|}} ((photo courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\ | ||
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| ===== 1967 XLH Cover ===== | ===== 1967 XLH Cover ===== | ||
| Sprocket cover part# (34871-67), with kickstarter. \\ | Sprocket cover part# (34871-67), with kickstarter. \\ | ||
| - | The 1967 XLH cover has a new cover casting and still has the single rib but it's modded for electric start motor. ((Moon Wolf of the XLFORUM http://xlforum.net/forums/showpost.php?p=3158885&postcount=3)) ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=6013853#post6013853)) \\ | + | The 1967 XLH cover has a new cover casting and still has the single rib but it's modded for electric start motor. ((Moon Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/112326-a-photo-catalog-of-ironhead-parts?postcount=3#post2359534)) ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205696-ironhead-sprocket-covers/page2#post4662203)) \\ |
| It's a 1 year, 1 model only, cover (machined for both kick and electric start as fitted from factory). \\ | It's a 1 year, 1 model only, cover (machined for both kick and electric start as fitted from factory). \\ | ||
| ===== 1968-1969 XLH Cover ===== | ===== 1968-1969 XLH Cover ===== | ||
| - | The original 1968-1969 XLH cover is HD part# (34869-68), with the upper dowel in the rear of the cover attaching bolt and machined for an optional factory kick start kit. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=6013853#post6013853)) \\ | + | The original 1968-1969 XLH cover is HD part# (34869-68), with the upper dowel in the rear of the cover attaching bolt and machined for an optional factory kick start kit. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205696-ironhead-sprocket-covers#post4662020)) \\ |
| The ribbed design matching the cam cover was removed for a smooth surface across the cover instead (often referred to as a moonpie cover). \\ | The ribbed design matching the cam cover was removed for a smooth surface across the cover instead (often referred to as a moonpie cover). \\ | ||
| The worm gear roll pin bore does not go all the way through to the front of the cover. \\ | The worm gear roll pin bore does not go all the way through to the front of the cover. \\ | ||
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| ===== 1968-1969 XLCH Cover ===== | ===== 1968-1969 XLCH Cover ===== | ||
| - | 1968-1969 XLCH also had a new smooth cover casting (moonpie cover) with the upper dowel pin location in the front of the cover attaching bolt. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=6013853#post6013853)) \\ | + | 1968-1969 XLCH also had a new smooth cover casting (moonpie cover) with the upper dowel pin location in the front of the cover attaching bolt. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205696-ironhead-sprocket-covers/page2#post4662203)) \\ |
| Sprocket cover part number (34872-57A), with kick starter. Casting number (74-52B). \\ | Sprocket cover part number (34872-57A), with kick starter. Casting number (74-52B). \\ | ||
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| ===== 1970 XLCH Cover ===== | ===== 1970 XLCH Cover ===== | ||
| - | There were two versions of the 1970 XLCH style kicker cover (both moonpie covers). ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=6013666#post6013666)) \\ | + | There were two versions of the 1970 XLCH style kicker cover (both moonpie covers). ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205696-ironhead-sprocket-covers/page2#post4662203)) \\ |
| First one was factory fitment on some/all 1970 XLCH. It has 1 upper dowel pin hole in the rear of the upper cover attachment bolt. \\ | First one was factory fitment on some/all 1970 XLCH. It has 1 upper dowel pin hole in the rear of the upper cover attachment bolt. \\ | ||
| The second version is machined for 2 upper dowel pin holes, 1 in front and 1 in the rear of the cover attachment bolt; \\ | The second version is machined for 2 upper dowel pin holes, 1 in front and 1 in the rear of the cover attachment bolt; \\ | ||
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| ====== 1977-1978 Transmission Sprocket Covers ====== | ====== 1977-1978 Transmission Sprocket Covers ====== | ||
| - | The 1977-1978 XLCH cover is recognizable from a couple of things. Most obvious is the small 1/4" hole located about 1" or less above the kicker shaft bushing hole. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?s=19d92dabb7ff8195321a60cc17f058a4&t=688077&page=2)) \\ | + | The 1977-1978 XLCH cover is recognizable from a couple of things. Most obvious is the small 1/4" hole located about 1" or less above the kicker shaft bushing hole. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/87428-which-sprocket-cover/page2?s=19d92dabb7ff8195321a60cc17f058a4&t=688077&page=2)) \\ |
| This is the mounting stud for the extra support bracket, which is a must have on 1977-1978 XLCH with a kicker if you dont want to crack the poorly mounted sprocket cover. \\ | This is the mounting stud for the extra support bracket, which is a must have on 1977-1978 XLCH with a kicker if you dont want to crack the poorly mounted sprocket cover. \\ | ||
| The other thing on the 1977-1978 cover is the half-inch hole for the footpeg mount at the bottom front of the cover, with small 1/8" dowel locating holes. \\ | The other thing on the 1977-1978 cover is the half-inch hole for the footpeg mount at the bottom front of the cover, with small 1/8" dowel locating holes. \\ | ||
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| Inner Sprocket Cover \\ | Inner Sprocket Cover \\ | ||
| - | The 1977 and 1978 years were unique in that there is another stamped steel inner cover (34893-75) under the aluminum sprocket cover. ((ericfreeman of the XLFORUM http://xlforum.net/forums/showthread.php?t=232588&page=2)) \\ | + | The 1977 and 1978 years were unique in that there is another stamped steel inner cover (34893-75) under the aluminum sprocket cover. ((ericfreeman 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)) \\ |
| The steel piece holds the rear brake cable and light switch. \\ | The steel piece holds the rear brake cable and light switch. \\ | ||
| Fortunately, HD made this cover just large enough to fit around a 23T sprocket, otherwise we'd be in for some serious modification work. \\ | Fortunately, HD made this cover just large enough to fit around a 23T sprocket, otherwise we'd be in for some serious modification work. \\ | ||
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| A 1/4"-20 x 1-3/4" posi-drive head screw (1308) was used thru the lower (hollow) dowel for extra clamp support on the sprocket cover. \\ | A 1/4"-20 x 1-3/4" posi-drive head screw (1308) was used thru the lower (hollow) dowel for extra clamp support on the sprocket cover. \\ | ||
| The L77 cover has an extra hole in the location for the screw although most folks swap the posi-drive screw to a phillips head screw. \\ | The L77 cover has an extra hole in the location for the screw although most folks swap the posi-drive screw to a phillips head screw. \\ | ||
| - | HD most likely added the fastener to help support an inherently weak cover when using the OEM folding kicker required by the big 2-1 muffler. ((ericfreeman of the xlforum http://xlforum.net/forums/showthread.php?t=945685)) \\ | + | HD most likely added the fastener to help support an inherently weak cover when using the OEM folding kicker required by the big 2-1 muffler. ((ericfreeman of the xlforum https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/105814-77-and-78-sprocket-cover-xlh-vs-xlch?t=945685)) \\ |
| This threaded hole may or may not go all the into the transmission case. \\ | This threaded hole may or may not go all the into the transmission case. \\ | ||
| If it does, you may need to add some thread sealer on the screw threads before installing it, or there will be some oil spillage there. \\ | If it does, you may need to add some thread sealer on the screw threads before installing it, or there will be some oil spillage there. \\ | ||
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| ====== 1979 XLCH Cover ====== | ====== 1979 XLCH Cover ====== | ||
| Outer Sprocket Cover (34872-79), polished, with kichstarter. \\ | Outer Sprocket Cover (34872-79), polished, with kichstarter. \\ | ||
| - | The master cylinder was mounted high on the 79's to miss the optional kickstarter shaft. Later models have no kicker. ((ryder rick of the XLFORUM http://xlforum.net/forums/showthread.php?t=667564&page=2)) \\ | + | The master cylinder was mounted high on the 79's to miss the optional kickstarter shaft. Later models have no kicker. \\ |
| Click on a pic to enlarge: ((photos courtesy of Ebay seller, WheatStateParts. [[https://www.ebay.com/str/cos0608|Link to Ebay Store]] )) \\ | Click on a pic to enlarge: ((photos courtesy of Ebay seller, WheatStateParts. [[https://www.ebay.com/str/cos0608|Link to Ebay Store]] )) \\ | ||
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| Here is how the inner cover fits in the outer cover. \\ | Here is how the inner cover fits in the outer cover. \\ | ||
| Also shown is how the rear brake linkage is connected over the cover with the return spring attached to the cover. \\ | Also shown is how the rear brake linkage is connected over the cover with the return spring attached to the cover. \\ | ||
| - | {{:techtalk:ih:engmech:1979_xlh-xlch-xls_inner_transmission_sprocket_cover_34899-79_by_hawghd1.jpg?direct&300|}} ((photo courtesy of Ebay seller, hawghd1 [[https://www.ebay.com/str/moschopshop?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:ih:engmech:1979_xlh-xlch-xls_inner_transmission_sprocket_cover_34899-79_by_1979ironhead.jpg?direct&300|}} ((photo by 1979ironhead of the XLFORUM http://xlforum.net/forums/showthread.php?t=667564)) \\ | + | {{:techtalk:ih:engmech:1979_xlh-xlch-xls_inner_transmission_sprocket_cover_34899-79_by_hawghd1.jpg?direct&300|}} ((photo courtesy of Ebay seller, hawghd1 [[https://www.ebay.com/str/moschopshop?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:ih:engmech:1979_xlh-xlch-xls_inner_transmission_sprocket_cover_34899-79_by_1979ironhead.jpg?direct&300|}} ((photo by 1979ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/86229-need-pic-of-79-rear-brake-linkage?t=667564)) \\ |
| ====== 1980 XLH Cover ====== | ====== 1980 XLH Cover ====== | ||
