Transmission 4 Starter C

Remove kick starter assembly from gear box as follows:

Place oil drain pan under transmission. Remove starter cover nuts (1) and plain washers (2). If transmission is in chassis, remove clutch lever rod from left end of clutch release lever. Cover assembly with clutch release lever assembly is then free to be pulled off mounting studs. Clutch release bearing (3) will come off with cover. If starter cover binds, release bearing is binding on starter clutch. Pry bearing off starter clutch. Do not pry cover for it will damage bearing. With starter cover removed, push rod (4) is free to be pulled out of mainshaft.

Clamp crank (8) in vise, bend ear of lock washer (6) away from flat of starter crank nut (5) and remove nut and lock washer (6). Remove starter gear (7) using the Harley-Davidson All Purpose Claw Puller, Part No. 95635-46. If puller is not available, remove starter crank from vise, and drive starter crank out of starter gear with rawhide mallet. Be sure to hold starter crank and cover from swinging when shaft is free from gear.

With starter gear removed, crank (8) can be pulled out of cover. Thrust washer (9) is installed between starter crank spring (10) and cover (11) with chamfered side of washer facing spring.

Remove nut (12) and lock washer (13), and pull release lever (14) from end of clutch release lever shaft (15) using All Purpose Claw Puller.

Remove cotter pin (16) and plain washer (17) from lower end of release lever shaft, which can then be pulled out of cover, freeing release finger (18) and thrust washer (19).

CLEANING, INSPECTION AND REPAIR (Fig. 4C-1)

Wash all parts in a grease solvent and blow dry.

Insert starter crankshaft in starter cover and check play. If play is appreciable, press out bushings (20) and install new parts. If transmission was leaking oil out starter crank, install new oil seal (21). Bushings are pressed in with outside ends just flush with bushing boss and outer surface of cover.

Bushings (22 and 23) rarely need replacement. However, check fit of release lever shaft and press out old bushings and install replacement parts if shake is considerable.

Check clutch push rod bearing for wear. Replace unit that grinds, feels rough or loose when rotated.

Check starter crank gear cam plate and gear pin to be sure they are in good condition, especially if starter crank bushings were replaced.

Install release lever shaft (15) and release finger (18) in cover with thrust washer (19) located between finger and bushing (23), and plain washer (17) and cotter pin (16) on end of shaft.

Install starter crank spring (10) and thrust washer (9) on starter crank with chamfer side facing spring, and apply a film of light grease on oil seal (21) and on end of starter crank shaft before installing crank (8). Hold crank in vise and wind spring by turning cover clockwise. Install starter crank gear (7) so dowel pin holds crank in normal, upward position. Install lock washer (6) and nut (5) and tighten nut securely. Bend over one ear of lock washer against one flat of nut. Install gasket (24) over studs on case.

Before starter cover is installed, clutch release bearing (3) is inserted into cover, with slot in outer bearing race engaging clutch release finger (18). Insert push rod (4) small diameter end into clutch release bearing and place the other end into main-shaft. With push rod serving as pilot, move cover assembly into place. Groove in clutch release bearing inner race and ball plunger in starter clutch must align so they will be engaged when assembly is completed. Turn on and draw up all cover nuts and washers.

Refill unit with 1-1/2 pints of same grade oil used in engine.

DISASSEMBLING STARTER CLUTCH (Fig. 4C-1)

Remove starter cover assembly as described in "Disassembling Starter," and proceed as follows:

Bend ear of lock washer away from flat of starter clutch nut (25) and remove nut and washer (26). Pull starter clutch (27) from mainshaft taper with Starter Clutch Puller, Part No. 95650-42. With starter clutch removed, starter clutch keys (28), starter mainshaft gear (29) and starter clutch spring (30) are free to be removed from mainshaft.

CLEANING, INSPECTION AND REPAIR (Fig. 4C-1)

Wash all parts except gasket (24) in grease solvent and blow dry with compressed air.

Examine teeth on starter clutch and starter gear (29), ratchet teeth on mainshaft gear and starter clutch. Teeth should be sharp edged. If teeth are rounded or mushroomed and rider has experienced ratchet slip, replace worn parts. If starter clutch nut has previously been drawn down too tight, starter clutch may be cracked. If cracked, it is usually difficult to get the starter clutch out of clutch release bearing when disassembling starter cover.

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