Ironhead kicker slipping

[a1953mdl]

I got my sporty started today,
When kicking it, the kicker would slip and not engage about 1 out of every 3-4 kicks.

I read a few threads on kickers here on the board and figured that the bushings, gears or drive was worn out.

I opened it up and found the clutch cover had a huge weld repair on it.


When I pulled the cover, about a cup of oil came out. I also noticed the basket was loose.
When I went to pull the nut, it was loose but the lock tabs were still bent over. I bent them back and removed the nut with my fingers.
After turning over the basket I found this


The gears and bushings of the kicker seem like new.
It looks like something had come loose in there and was only partially repaired. The nut holding the gear on the kicker shaft was chewed up, but the gear was in great shape.


Is it possible that the chewed up, poorly repaired back side of the clutch basket is causing the kicker to slip every so often?

Anyway I guess I'm looking for a complete clutch, basket, cover and usable discs. Is there anything else I need to look for or check or consider replacing?

Thanks for the help.
Lee
1969 kickstart only magneto sportster

[Hopper]

Yep I would agree with your diagnosis.
Hopper's rule of thumb: Most mechanical problems are related to the last thing that was worked on.
Looking at the quality of workmanship there, I would say the chances of that ratchet plate being rivetted to the clutch straight and true are pretty damn slim. That would cause your problem.
Wise move to get a new clutch body. If you get one with a worn ratchet, you can rivet a new one on, but need to use a centralising tool and clamps to make sure it runs true.

Other stuff: New locktag and nut and maybe Loctite on the splines if they are worn.
New primary chain and tensioner while you are in there?
Also put a new bearing in the clutch basket, if they wear and wobble about, that can make the kicker slip too.

[a1953mdl]

Hopper,
Thanks for the heads up on the bearings. Thats exactly the type of info I was looking for. Is there a easy way to check the bearings? Several items look new in there and don't want to replace a new item.
Lee

[72 Ironhead XLH]

just a guess but where is the spacer between the hub and the input shaft?
Only way i see to gouge it up like that is with no spacer installed.

[a1953mdl]

I'll compare what I have to a diagram in the service manual. Not sure what is suppose to be there and what is not. Thanks for letting me know about the spacer, that could explain a lot.
Lee

[72 Ironhead XLH]

VT shows 17-1103 for the ratchet gear kit and spacer 17-1100 (1954-1970)

[fdny37]

I am a bit curious as I see you have a electric start clutch basket on a kick only '69. On the '68 CH I am building an electric start basket will not even fit in the primary case, the ring gear hits on the top of the case. You need to get a parts manual to have the exploded view of all the parts and the position that they assemble. I see that you have some added components with that Trock iron trap door.

[a1953mdl]

I am glad I like a challenge, cause it seems I may be in for one.
I've had many sportsters, but never got to know them that intimately.
I have figured out that this is a "pieces and parts" bike, but I don't know what is which.
I guess the ring gear on the outer part of the basket should have been my clue.
Is trying to find a kick start only clutch the right idea here? Or does it make any difference as long as it fits the case?

[a1953mdl]

Does any one have a picture of what mine should look like.

[fdny37]

A kick only basket is basically the same as yours only without the ring gear.