Starter Crank Gear

7. Install the kickstarter gear lockwasher and nut. Tighten the nut to 50-60 ft.-lb. (69-82.8 N.m) (1966-early 1978) or 30-40 ft.-lb. (41.4-55.2 N.m) (late 1978-on). Bend the lockwasher tab over the nut to lock it.

Starter Clutch Removal/Inspection/Installation

Refer to Figure 120 or Figure 121 for this procedure.

1. Remove the kickstarter side cover as described under Removal!Installation in this chapter.

2. Remove the pushrod (Figure 125).

3. Lock the transmission into 2 gears at once.

4. Bend the lockwasher tab away from the starter clutch nut (Figure 133).

5. Remove the starter clutch with the Harley-David-son starter clutch puller (HD-95650-42). See Figure 134.

6. Remove the Woodruff key, starter clutch gear and spring.

7. Check the starter gear and starter clutch teeth. Teeth should be sharp and show no signs of cracking, scoring or excessive wear. Replace starter clutch and starter gear if teeth are rounded or if the kickstarter has been slipping.

8. Visually check the starter clutch for cracks, deep scoring and excessive wear.

9. Slide the starter gear on the main shaft and check side play by hand. If gear is loose, have the bushing replaced by a Harley-Davidson dealer or machine shop. Do not attempt to drive a new bushing into the gear.

10. Installation is the reverse of these steps. Note the following:

a. Lubricate the main shaft with engine oil.

b. Install the spring and starter gear onto main shaft.

c. Push the starter gear toward the transmission and release it. The spring should be able to push the gear forward. If the gear is tight, the gear bushing should be reamed. Refer this service to a Harley-Davidson dealer.

d. Press the starter clutch onto the main shaft.

e. Tighten the starter clutch nut to 34-42 ft.-lb. (46.9-57.9 N.m). Bend the lockwasher tab over to lock the nut.

SIDE COVER (ELECTRIC START)

Removal/Disassembly

1. Refer to Figure 135 for this procedure. Disconnect the negative battery cable.

2. Drain the transmission oil as described in Chapter Three.

3. Remove the exhaust system as described in Chapter Seven.

4. Remove the rear master cylinder reservoir. See Chapter Twelve.

5. Remove the clutch cover (Figure 122) on the primary cover.

6. See Figure 123. Loosen the pushrod locknut and turn the adjusting screw counterclockwise to remove all tension on the pushrod.

7. Remove the starter bracket.

8. Remove the side cover mounting bolts and remove the side cover and gasket.

9. If necessary, disassemble the side cover as described in this chapter.

10. Installation is the reverse of these steps. Note the following.

11. Install a new side cover gasket.

12. Pull the pushrod assembly partway out as shown in Figure 125.

13. Position the release lever to the left of the cover as shown in A, Figure 126.

14. Align the pushrod oil slinger (Figure 127) with the release lever mechanism (B, Figure 126) and install the side cover. The lever should face as shown in Figure 128.

15. Install the side cover mounting bolts and tighten them to 13-16 ft.-lb. (17.9-22.1 N.m).

16. Refill the transmission with the correct type and quantity of oil as described in Chapter Three.

17. Adjust the clutch as described in Chapter Three.

Disassembly/Inspection/Assembly

Refer to Figure 135 for this procedure.

1. Remove the release lever nut and washer.

2. Pull the release lever off of the shaft with a universal type claw puller.

3. Remove the clip. Then remove the shaft from the cover.

4. Remove the release finger and washer.

5. Clean all components thoroughly with solvent. Remove any gasket residue from the cover-to-trans-mission machined surfaces. Check the threads in the transmission case to be sure they are clean. If dirty or damaged, use a tap to true up the threads and remove any deposits.

6. Visually check the shaft surfaces for cracks, deep scoring, excessive wear or heat discoloration.

7. Slide the release lever shaft into the side cover. Check the shaft-to-bushing wear by moving the shaft back and forth. If there is excessive shaft wear, replace the upper and lower bushings with a blind hole bearing remover and slide hammer. Have a Harley-Davidson dealer or machine shop press in the new bushing.

8. Assemble the release finger as follows:

a. Install the washer and release finger into the side cover.

b. Insert the release lever into the side cover and through the release finger and washer. Secure the shaft with a new circlip.

c. Install the release lever. Then install the lock-washer and the nut. Tighten the nut until the release lever bottoms on the shaft.

ELECTRIC STARTER DRIVE Removal (Type I)

The Type I electric starter drive (Figure 136) is used on the following models:

b. All FX chain driven models.

1. Disconnect the negative battery cable.

2. Remove the starter as described in Chapter Seven.

3. Remove the primary cover as described in this chapter.

4. Remove the drive gear housing bolts (1, Figure 136) and remove the drive gear housing (12).

5. Remove the oil deflector (3) and gasket (4).

0 0

Post a comment