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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #31  
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OK. I won't comment on any other threads but I'll finish off this thread.

Finished riveting the kicker plate on. It appears to be good. These have to be centered correctly or the bush in the gear can hang up on them and the teeth won't fully engage.

I was happy the clearance looks to be just 0.001. Can't get any better.

Actually, on the note, I did measure before I started but as careful as I was, I was wrong. But having the full set of shims allowed me to do selective assembly and turned out the correct one was 0.975. No where near the 0.930 I measured.

So:

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  #32  
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You really do need tools to do this right. So, this is the jig and the punch.

It will go into my collection of other tools I'll probably never use again now.

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Yeh but you done it right.
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Most of the tools are quite simple things really. Well, compared to the computers required on any car built after the year 2000.

Now I have to measure/adjust the spacer and kicker bush and I can finish putting the gearbox in and the primary on.

This is another area that just requires hand fitting. A bronze bushing sliding on a steel tube. After market spacers all seem to be made over size. Maybe someone makes them closer to spec but there's no need for both the bushes and the spacers to be made over size. Anyway, I'll just get it done. Whoever winds up kicking this thing over will appreciate it. I hope.
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impressive.you know i/we'd like to see more of that 1958 XLCH assembly.
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I can't even remember now if I took pics before I put the cases together.

I had it in my head that KHK flywheels came polished from the factory. So, thinning nothing that far out of the ordinary.

I've since been told they weren't. Someone went to the trouble.

The heads have been ported, but I don't know who by. So, might be really good, might be terrible. Pistons are Axtell (Sorry, I forget now)) 2 ring stroker pistons.

I never worried too much about documenting this one. Just a play toy thing for me. I am not going to race it so, doesn't matter that much.

All the hard work was done by someone else before I got it. Cases relieved for rods, bored for cylinders, shafts replaced etc. So. nothing hard or unusual about it.

I bought it in large chunks. I don't think the sellers really understood what they had. They could have got a LOT more for it if they had left it all together.

I didn't get the gearbox or primary but all the serious stuff was there.

I'll have a look when I can to see if I did take dome pics.
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Quote:
Originally Posted by Ferrous Head View Post
You really do need tools to do this right. So, this is the jig and the punch.

It will go into my collection of other tools I'll probably never use again now.


No sheet, great work that is.
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"Finished riveting the kicker plate on. It appears to be good. These have to be centered correctly or the bush in the gear can hang up on them and the teeth won't fully engage."

Nice, looks to be genuine machined ratchet plate. Ever look at an AMF plate? Extruded copper Done with a single destructive smash of metal. Just looks like $hit compared to that thing of beauty you have mounted. Hand fit the kicker gear and a fresh bushing and that thing will never slip.
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I hadn't started out to make this a documentation thread on kicker set ups. It's not something I would normally do. In fact, originally I wasn't going to bother with putting a kicker on it.
The clutch shell was new but without a kicker plate. It was the only shell I had left unless a "borrowed" from another project.
But I had a lot of other NOS parts, almost enough to install the kicker, so thought I might as well.

I'm stalled at the moment anyway as it seems I've lost most of my oil pump spare parts. Small things like dowels and gaskets. So I have to stop and order them and a few other "odd" parts for this engine.

I'll get on to Redgraves again seeing they seem to be such a good source for obsolete parts.
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