Kick Starter

DISASSEMBLING KICK STARTER (Figure 4-7)

Remove kick starter assembly from gear box as follows:

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. With starter cover removed, push rod assembly (3) is Iree 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 retaining ring (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 (Figure 4-7)

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 replace bushings if shake is considerable.

Check clutch push rod bearing (3C) for wear. Replace unit that grinds, feels rough or loose when rotated.

Check cam plate and gear pin on starter gear (7) to be sure they are in good condition, especially if starter crank bushings were replaced.

ASSEMBLING KICK STARTER (Figure 4-7)

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 retaining ring (16) on end of shaft.

Install starter crank spring (10) and thrust washer (9) on starter crankshaft (8) with chamfer side of washer 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 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 oil used in engine.

Adjust clutch.

Adjust rear brake pedal.

DISASSEMBLING STARTER CLUTCH (Figure 4-7)

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

Bend ear of lockwasher (26) away from flat of starter clutch nut (25) and remove nut and washer. 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 (Figure 4-7)

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

Examine teeth on starter clutch (27) and starter gear (29). Teeth should be sharp edged. If teeth are rounded or mushroomed and rider has experienced ratchet slip, replace worn parts. If starter clutch has previously been drawn down too tight, starter clutch may be cracked, If cracked, replace it.

Exploded View Harley Speed Clutch

1. Starter cover nut (9)

8A.

Crank

17.

Plain washer

25.

Starter clutch nut

2. Plain washer (9)

8B.

Bolt

18.

Release finger

26.

Starter clutch washer

3. Push rod assembly (3A to 4)

9.

Thrust washer

19.

Thrust washer

27.

Starter clutch

3A. Oil slinger

10.

Starter crank

20.

Starter crank

28.

Starter clutch key

3B. Thrust washer

spring

bushing (2)

29.

Starter mainshaft

3C. Thrust bearing

11.

Starter cover

21.

Oil seal

gear

3D. Thrust washer

12.

Release lever nut

22.

Release lever

30.

Starter clutch spring

3E. Lock ring

13.

Lockwasher

bushing (upper)

31.

Mainshaft gear

4. Push rod

14.

Release lever

23.

Release lever

bushing

5. Starter crank nut

15.

Release lever

bushing (lower)

32.

Starter spring stud

6. Eared lockwasher

shaft

24.

Starter cover gasket

33.

Starter crank stop

Figure 4-7. Kick Starter and Clutch Release Assembly — Exploded View

Figure 4-7. Kick Starter and Clutch Release Assembly — Exploded View

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

ASSEMBLING STARTER CLUTCH (Figure 4-7)

Coat gasket (24) with gasket sealer and position on transmission case. 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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    How to loosen clutch pushrod nut shovelhead?
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