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  #1  
Old 6th February 2010
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Default '77 & '78 Kick Support

Pics followed by description ...











Pipe is 1,1/4" OD. ID is larger than the 7/8" ID of the holes in the end fittings. I can feel with finger that the pipe has a larger ID than the holes in the fittings on either end. The pipe is probably 1" ID. So pipe is 1/8" thick.

The length of the pipe measured between the two end fittings measures 2,43/64"; so is probably 2,11/16".

The threaded hole in the smaller end fitting is 1/4", same thread as cover bolts. The bolt that goes thru there is 1" in length. Center to center with pipe hole is 1,5/16".

The two unthreaded holes in the case end fitting are 3/8", center to center is 2,11/16". Center to center 1,7/8" and 1,1/8" with the big hole. Check these against the bolts that it mounts to on the case, and against the hole for the shaft.

Cutout hole is 5/8" ID.

Really needs a CAD or whatever drawing to accurately portray the shapes/dimensions of the end fittings.
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Old 6th February 2010
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that should help prevent any case cover cracking.
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Old 7th February 2010
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This is a Harley Davidson part that was not included in original bikes from the factory. It is a fix they came up with because of the problem of breaking sprocket covers on these models. Hard to come by, so you may want to make your own. Which is the purpose of this post.
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Old 7th February 2010
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Back in the Iron Age, before CAD, we used to do drawings by crushing charcoal from the fire at the mouth of the cave and mixing it with our own blood to make ink and using a Dodo bird feather for a quill.




Link to bigger drawing here (I think!):
http://i249.photobucket.com/albums/g...ktcvr005-1.jpg


And not shown on the drawing is this stock divot cut out of the support tube to allow the oil supply line to run through there without being pinched. I had to grind a similar but not so severe divot a little further outboard too, to provide clearance for the 23-tooth sprocket.

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Old 7th February 2010
66xlch 66xlch is offline
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I love that part, and I dont know why they only did it for '77-'78s. I broke my '66 cover, and judging by all the welded early covers out there so have lots of others. I'm going to make one for my 'ch for sure.
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Old 7th February 2010
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Quote:
Originally Posted by 66xlch View Post
I love that part, and I dont know why they only did it for '77-'78s. I broke my '66 cover, and judging by all the welded early covers out there so have lots of others. I'm going to make one for my 'ch for sure.
Because the 77-78 sprocket cover mountings were even dickier than the earlier models, using 1/4" philips screws made from cheese metal instead of the earlier 5/16 or larger bolts.

See this thread here for how I welded a pad inside my early 77 sprocket cover for this support bracket to attach to. I imagine you could do similar to an earlier model.
This thread:
http://xlforum.net/forums/s...d.php?t=232588

It also shows how I built an extra support bracket from the top of the gearbox where the breather attaches to the top of the sprocket cover for extra support. Could be used on earlier models that break that aluminum mount tag off the top of the gearbox casing.
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Old 7th February 2010
66xlch 66xlch is offline
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Yeah, I have one of your later covers in a box somewhere, and it is extra flimsy!
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Old 7th February 2010
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Quote:
Originally Posted by IronMick View Post
This is a Harley Davidson part that was not included in original bikes from the factory. It is a fix they came up with because of the problem of breaking sprocket covers on these models. Hard to come by, so you may want to make your own. Which is the purpose of this post.
Mick, I bought that part from Billscustomcycles.com last year. Seems to me it was about 15-20 bucks. When I installed it I drilled and tapped the 1/4 hole on the support bracket out to 5/16 and then used a 5/16 shoulder bolt for a tight fit thru the cover. Havn't broken a cover since.
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Old 7th February 2010
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Quote:
Originally Posted by daler View Post
Mick, I bought that part from Billscustomcycles.com last year ...
I got mine from NOSParts.nl. I think i paid at least twice what you did. I don't want to look!

Last edited by IronMick; 26th September 2013 at 12:35.. Reason: sp
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Old 8th February 2010
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Quote:
Originally Posted by daler View Post
I installed it I drilled and tapped the 1/4 hole on the support bracket out to 5/16 and then used a 5/16 shoulder bolt for a tight fit thru the cover..
Yes, I did that too, as well as drilling and tapping the two main mounting bolt holes so I could use 5/16" high-tensile allen head bolts instead of the cheesy 1/4 phillips head screws. Maybe a little bit of overkill - but I dont have estart so the kicker gets a lot of use.
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