Kick Starter


Place oil drain pan under transmission. Remove starter cover nuts (1) and plain washers (2). Loosen clutch adjusting screw (2, Figure 4-4). If transmission is in chassis, remove clutch lever rod from left end of clutch release lever. Remove exhaust pipe and other components mounted on transmission cover studs. Cover assembly with clutch release lever, assembly is then free to be pulled off mounting studs. Clutch push rod assembly (3) will come off with cover. If starter cover binds, push rod is binding on starter clutch. Pry push rod 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 crankshaft (8) in vise, bend ear of lockwasher (6) away from flat of starter crank nut (5) and remove nut and lockwasher (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, crankshaft (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 lockwasher (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).

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 crankshft (8) with chamfer side facing spring. Apply a film of light grease on oil seal (21) and starter crankshaft before installing. Install starter crank gear. When viewing end of gear, notch on crankshaft (8) should be in 12 o'clock position and dowel pin on gear should be in 7 o'clock position. Install lockwasher (6) and nut (5) and tighten nut to 50 to 60 ft-lbs torque. Bend tab on washer up against flat on nut.

Before starter cover is installed, push rod assembly (3) is inserted into cover. Insert small diameter end of push rod into mainshaft. With oil slinger (3A) in cover and using push rod as a guide, move cover assembly into place. Dowel pin on starter gear must clear front of starter crank stop (33). Tighten all cover nuts (1) to 13 to 16 ft-lbs torque. Install starter crank (8A) and tighten crank bolt (8B) to 25 to 30 ft-lbs torque. Wind spring by turning it with a pliers clockwise and hooking end onto starter crank stud (32).

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

Adjust clutch. Adjust rear brake pedal.


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

Bend ear of lockwasher 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.


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.

Position mainshaft gear (29) on shaft and check play. If obviously loose, replace bushing (31).


Coat gasket (24) with gasket sealer and position on gear box. Lubricate mainshaft with engine oil and slip spring (30) and mainshaft gear over shaft. Bushing should be loose enough on mainshaft to allow gear to slide under force of compressed starter clutch spring. If necessary, line ream bushing to achieve free fit.

Position starter clutch, drive in starter clutch keys and assemble remainder of parts in reverse order of disassembly.

Tighten nut (25) to 50 to 60 ft-lbs torque.

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