OSKRG Research/Restoration Bulletin #7 Sportsters Kick Starter Parts This research and restoration bulletin was created with input and

Transcription

1 OSKRG Research/Restoration Bulletin #7 Sportsters Kick Starter Parts This research and restoration bulletin was created with input and assistance from members of the OSKRG. The report consolidates the best available information at the time of creation and may be updated or revised at a future date. If errors are identified, or there is additional information on the subject of this report that has not been included, please post comments, corrections or additions to in the Forum.

2 Sportster Kick Starter Parts OSKRG Part 7926 & Starter Shaft Nut & Starter Crank Gear Lock Washer 8241 Starter crank Gear Cam Plate Rivet Spring, Starter Ratchet Starter Crank Gear Stop In Crankcase Starter Crank Oil Seal A Kick Starter Shaft Bushing Starter Crank Gear Starter Crank Gear Cam Plate Kick Starter Shaft Thrust Plate Starter Crank Shaft Starter Crankshaft Bolt (Starter Crankshaft) 6092 Washer (Starter Crankshaft) Plug, Crankcase Starter Shaft Hole 8215 Rivet (For Starter Ratchet) 8216 Rivet (For Starter Ratchet) Model Years 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters 57-* All Sportsters XL, XLH, XLCH 67-* XLCH 67 XLH 67-* XLH 67-* XLH 68-* XLH All Sportsters 71-* XLCH

3 Part Spacer, Clutch Sprocket (long) Spacer, Clutch Sprocket (short) Spacer, Clutch Sprocket (long) Spacer, Clutch Sprocket (short) Spacer, Clutch Sprocket Spacer, Clutch Sprocket (long) Spacer, Clutch Sprocket (long) Early Gear, Starter Ratchet A Gear, Starter Ratchet Late Gear, Starter Ratchet Gear, Starter Ratchet with Bushing Bushing, Starter Ratchet Gear A Bushing, Starter Ratchet Gear Bushing, Starter Ratchet Gear Starter ratchet Starter ratchet A Starter ratchet 6469 Washer (For Starter Crank Gear Stop) 6802 Shim, Starter Crankshaft Kick Starter Shaft Collar Model Years XL, XLH, XLCH XLCH XL, XLH, XLCH 71-Early 73 XLCH 71-Early 73 XLH, XLCH 67-* XLH 79-XL & XLS All Sportsters XLCH Late 73-Early 75 XLH All Sportsters All Sportsters 57-Early 73 Late 73-* XLCH 57-Early 73 All Sportsters All Sportsters Late 73-* XLCH All Sportsters 71- All Sportsters 71-* All Sportsters 61-* All Sportsters 54-* All Sportsters As Required All Sportsters C H C H C H E 73 E 73 L 73 E 73 L 73 E 73 L 73 L 75 E 75

4 Part A Crankshaft, Starter Gear, Starter Crank Starter ratchet & Ratchet Gear Kit 8215 Rivet Starter Ratchet Gear, Starter with Bushing Spacer, Clutch Sprocket Starter Ratchet Gear Kit Gear, Starter with Bushing Spacer, Clutch Sprocket Model Years 77 to Early to Early All Sportsters See the following page to read the HD Service Bulletin No. 618C that addresses the use of these kits for starter replacement. 71-* XLH, XLCH See the following page to read the HD Service Bulletin No. 618C that addresses the use of these kits for starter replacement How to interpret the Table: If a part numbers Year Square (57-79) has color in it, it will work with any other part with the same year square that has color in it with the exception of Kits (I think?). Green indicates it was the original PN for that model year. Red indicates it is a later version of the part that will work in place of the original part. Yellow indicates uncertainty, more documentation needed.

5

6 Starter Ratchet Gear & Starter Ratchet Model Compatibility Green Compatible Yellow Unknown Presently Red Not Compatible -57 Ratchet Gear (18 Tooth) -57 Ratchet Gear (9 Tooth) -57A Ratchet Gear (Teeth # Unknown) -73 ratchet Gear (9 Tooth) Original 18 Tooth -57 Starter Ratchet (Small ID) 2 nd Version 9 Tooth -57 Starter Ratchet (Small ID) 3 rd Version 9 Tooth -57 Starter Ratchet (Big ID) -71 Starter Ratchet 9 Tooth -71A Starter Ratchet 9 Tooth Aftermarket Compatibility My finding using Harley OEM Parts is stated to the left, I found that the early version of the ratchet gear with 18 teeth would only properly mesh with the 18-tooth ratchet plate. As seen with the above Eastern aftermarket parts this does not appear to be the case. Their Kit uses an 18-tooth ratchet gear with a 9-tooth ratchet plate. Notice the note on the label indicating the bushing will need to be honed.

7 Comments about the XLH Kickstarter and Other Post 67 Sportster Issues By Bob Evans As we know all Sportsters were kick start only up to and including the electric start XL appeared and all XLH models left the factory with both push button and kick starting as a fail-safe it would appear. But the electric start Sportsters worked so well that the kick option was discontinued for 1968 XLH's. But the cases were still machined for a kicker shaft to be retrofitted thereafter. The kicker hole on 1968 and later XLH's was plugged by p/n So, for 1967 through 1969 there were two sets of Sportster crankcases and two separate frames for the XLCH and XLH. AMF took over H-D in the fall of 1968 and about the same time DOT, (Department of Transportation), was dictating changes for motorcycle manufacturers. Blending the two together, (AMF/H-D & DOT), changes would come to Harley Davidson. DOT, citing crash compiled statistics ordered ALL highway use cycles must have a front brake activated light switch. This is why 1969 XL's have this running change as well as front and rear fender side reflectors. For 1970 ALL highway use cycles are required to be able to have headlights remain on with the engine not running. For two reasons this was a no brainer for AMF/H-D; Great excuse to get rid of the rather expensive and complaint riddled magneto, and while they were at it AMF said why not 'communize' both XL models. So, for 1970 we have only one set of crankcases and one standard frame for two models turn signals became required per DOT on ALL highway cycles. And finally, for 1975 standard left side shift and right-side braking was required. To me this is the strangest thing; DOT told the industry in 1969 that 1975 would be the year for standard shifting required. Yet H-D waited until the 1975 model year was at the doorstep to do the half assed right to left conversions on the Sportsters for 1975 & 1976 while at the same time completely redesigning the Sportster bottom end for the 1977 models with the shifter properly exiting the left side crankcase and changing to an untimed gyrator oil pump and mini sump based on XR750 developments from (Observe in your parts books that 1977 & later Sportster crankcase, oil pumps and shifter shaft parts are all 1975-part numbers!) So, through all of these years from 1970 forward any Sportster could be made a kick or electric start or both. This continued to and including 1980 as the cases were still machined with kicker shaft holes, even though kick start Sportsters, (so called XLCH's), were finished production in For 1981 the new Hitachi starter was introduced requiring a redesign of the left case half and the kick shaft hole was no more. In 1982 the new frame and rear engine mount were introduced further eliminating any possibility of a return of a kick starter on any Sportster. Regards, -Bob-

8 Component Identification Information & Images 7926 & Starter Shaft Nut & Starter Crank Gear Lock Washer Nut ½-20 x 9/32 x 1-3/16 h ex 8241 Starter crank Gear Cam Plate Rivet 3/16 x 5/8 x 11/32 dia. ctsk. hd. (4) Spring, Starter Ratchet Starter Crank Gear Stop In Crankcase Starter Crank Oil Seal A Kick Starter Shaft Bushing

9 Starter Crank Gear Starter Crank Gear Cam Plate Can be distinguished from the -78 gear by the relative position of the centerline through the square shaft hole and round hole to the gear teeth. The line falls about 3 & ½ teeth to the left of the cam plate ramp. You can tell it from the -52A gear by the gears larger OD & it has a raised area on one side around the square hole You can distinguish the -57 cam plate from the - 52 & -52A plates by the -57s larger size. You can tell it from the -78-cam plate by the relative position of the closest rivet holes to the cam plates ramp. On the -57 the holes are in line with the edges of the ramps. They are not on the -78.

10 Gear, Starter Crank You can identify the -78 Crank Gear by the relative position of the centerline through the square and round hole to the cam plate ramp. For the -78 gear it is about 1 & ½ teeth. For the -57 gear it is about 3 & ½ teeth Kick Starter Shaft Thrust Plate Starter Crank Shaft Starter Crankshaft This Starter crankshaft can be identified by the 18 degree offset between the squared ends of the shaft and the Collar. What distinguishes it from the -52A K Model shaft is the squared end that holds the crank gear is about.42 rather than about.25 on the -52A Only Crankshaft with Female Threaded Left Side

11 A Crankshaft, Starter A Bolt (Starter Crankshaft) Bolt 5/16-24 x ¾ hex. Hd Washer (Starter Crankshaft) Plug, Crankcase Starter Shaft Hole Washer 1/16 x 1-1/8 x 3/ Rivet (For Starter Ratchet) 8216 Rivet (For Starter Ratchet) /32 x 13/16 x 9/32 dia. ctsk. hd. (12) 5/32 x 7/16 x 9/32 dia. ctsk. hd. (12)

12 Spacer Information from HD Service Bulletin No. 618C 73 PB Supplement Information showing factory dimensions of length for some spacers. From the 74 Service Manual. The Late 73 & Later Spacer is the Note: I find it interesting that the 73 Supplement, the 74 Service Manual and the No. 618 Service Bulletin show different sizes Spacer, Clutch Sprocket (Long) Spacer, Clutch Sprocket (Short)

13 Spacer, Clutch Sprocket (Long) Spacer, Clutch Sprocket (Short) Spacer, Clutch Sprocket (Long) Spacer, Clutch Sprocket (Long) Spacer, Clutch Sprocket Length=1.151 OD=1.628 Thickness=.223 ID=1.184 Spacer has No Flange

14 Gear, Starter Ratchet The original version of the Gear had 18 teeth, the later had 9. This Gear will work with all 3 versions of the -57 Starter Ratchet A Gear, Starter Ratchet Gear, Starter Ratchet with Bushing A I do not have a sample of this gear in hand to dimension it but based on Parts Books and Service Bulletins I believe it to be dimensionally the same as the -57 gear with the only difference being its -57A bushing. Because of issues with the bushing it was recommended that it be replaced with the previous gear and bushing used, the HD Service Bulletin No. 618A dated August 25, 1972 States Kick starter clutch gear assembly, part No , with bronze bushing should be used exclusively for replacement instead of gear, part No A, which has a bronze plated steel bushing. HD Service Bulletin No. 618B dated August 17, 1973 states New parts, as a parts assembly only are reccomended for replacement in all 1971 to present XLCH engines. New parts cannot be interchanged with earlier parts individually, they must be used together. Note: old parts will no longer be sold when present stock is depleted. The assembly of parts being referred to are the -73 kick starter gear, bushing and spacer. Note: I believe some or all of the 1971 bikes would have used a -71 starter ratchet. This ratchet has the small ID like the first and second versions of the -57 ratchet. The -73 starter gear and bushing will not fit it This Gear will only work with the later third version of the - 57 Starter Ratchet.

15 Bushing, Starter Ratchet Gear Version #1 Version #1 Bronze Note: Measurements made by me on new and used parts Bushing, Starter Ratchet Gear Version #2 Version #2 Has 3 holes rather than an X. Bronze Note: Measurements made by me on new and used parts A Bushing, Starter Ratchet Gear Version #3 Image not of a -57A bushing. Version #3 Bronze plated steel bushing. Steel bushings were used in production during the 71 model season and are easily recognized by steel color on the outside surface. This 57A bushing had problems (see the Service Bulletin No. 618 that follows). If this bushing was to be replaced HD recommended it be with the -57 bushing. HD Service Bulletin No. 618A dated August 25, 1972 states The recommended gear, part No is listed in your 1972 Sportster parts catalog supplement. Also listed is the replacement bronze bushing for this gear, part No However if this bushing is used to replace a steel bushing, it must be reamed or machined to I.D. after pressing into gear. The amount of material to be removed from the inside diameter is approximately.020 in. Do not hone this material out because grinding particles will imbed into bronze material and wear out the clutch sprocket spacer.

16

17 Bushing, Starter Ratchet Gear Note: Measurements made by me on new and used parts Starter ratchet-original Version, came out in Starter ratchet-second Version, came out sometime after Starter ratchet-third Version, came out in 73? Transitioned from 18 to 9 teeth sometime after 57. When unclear at this time. The - 73 Starter Ratchet Gear will NOT work with this Ratchet. This ratchet plate has only 9 teeth but is dimensionaly the same as the first version with 18 teeth. The -73 Starter Ratchet Gear will NOT work with this Ratchet Have only observed this second version with 9 teeth. The - 73 Starter Ratchet Gear will work with this Ratchet. Notice the ID of this plate is larger.

18 Starter ratchet I believe this part was used for all or most of Note that it has a smaller ID than the -71A. ID = 1.51 Note: Measurements made by me on new and used parts A Starter ratchet 6469 Washer for Starter Crank Gear Stop 6802 Shim, Starter Crankshaft A I believe this part was used from 72 on. Note that it has the larger ID to accept the -73 starter gear and bushing. ID = 1.58 Note: Measurements made by me on new and used parts. Washer 7/16 x ¾ x 1/8 Shim/Washer ¾ x 1-1/16 x.007 Steel (As Required) Kick Starter Shaft Collar

19 57 Parts Book 59 Parts Book

20 63 Parts Book

21 63 Parts Book Continued

22 65 Parts Book

23 65 Parts Book Continued

24 67 Parts Book

25 67 Parts Book Continued

26 81 Parts Book Covering 79 XL & XLS

27 81 Parts Book Covering 79 XL & XLS

28

29