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

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  #1  
Old 17th October 2008
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Default Kickstart Conversion Kits

I found these kickstart conversion kits online (tejasthumpcycles.com). I'm thinking of converting my 82 Ironhead to a kickstart, but not sure what will work best (if anything).
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  #2  
Old 17th October 2008
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Last year of kickstarts was officially 1979, although some 1980's had cases with the hole/bushing for kickstarts. No chance on 1982 without serious machine work.

Eric
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  #3  
Old 19th August 2010
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I know this is a old thread, but everyone talks about this.

I have a 1982 ironhead as well and had my starter realy die about 30 miles from home last weekend. A buddy pushed me up the next hill and i did a 2nd gear bump start...

Anyway, it got me thinking about how to convert my 1982 to a kicker.

I have installed MANY a kicker on older ironheads and actually have a complete 'backup' kicker kit sitting around that i have been comparting to my 1982...

If im not mistaken, the clutch basket on the 1982 WILL accept the ratchet plate.

The 'Serious Machining' everyone mentions seems to boil down to drilling a hole in the rear motor mount and the inside of the primary case in the engine block for the kicker shaft. Then the sprocket cover and rear brakes need to be converted to 1979 specs.

This does not seem difficult at all if you take the cases apart.

I just finished re-doing the bottom end and will not be splitting my cases again so soon, so am i crazy to think that i can lay the bike over on its primary side and true it to my drill press to get a good clean hole in the case?
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Old 19th August 2010
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so i'm thinking. . .the hole is what 3/4"? . . or around that, what sort of tolerance . .say less than 1mm . .too far away and your gears will not have a full mesh, too far in and it will all bind and lock up. . . . your going to have issues there unless your mighty lucky!!
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Old 19th August 2010
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I was once told by someone "not completely full of it" that basically that it. yes the hole location is critical but and good machine shop could do that one ( I dont know the definition of serious machine work but, after what I've been through with my guy this dont seem so well SERIOUS.. His was done by a dealership no less which had a wrench who had started in the AMF era. Soooo... even though I've been told "no it aint happening" the next time my cases are aprt I'm doin it. o yea E84
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Old 19th August 2010
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im not sure what the inside of your primary looks like on the newer ironheads, but here's my early 80 that had the hole in it for the kicker(which is now fitted) you can use this as a reference to see what you might have to do to get it to work on the newer bikes.
good luck with this adventure.

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  #7  
Old 19th August 2010
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Here's a question: How bad would it be to just find a set of older cases? The stroke should be the same in all the motors, and the studs from the case to the jugs shouldn't have changed, so if I'm looking at all this right, if you find an older set of cases, you can just switch it all over with the added benefit of knowing the hole is in the right spot.

I'm new to ironheads, so take that into account for whatever I say.
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Old 19th August 2010
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man, my knee hurts reading this post. I grew up on a '65 and '68. How many times did that pedal jam my knee? After three kicks with a magneto, it was time to take off the coat and helmet. Why anyone would want a manual leg after owning an electric leg is beyond me. It was nice when a big ape azzholes couldn't do what a 140 lb wuzz could. But, that little button is nice after a couple brew after two.
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Old 19th August 2010
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I can't speak for everyone wanting to do this, but my reason is that it's a vintage feature, that you can't get on new bikes. My ironhead is older than me. Having a kick start just adds to the "old skool" look. In my case, I'm not sacrificing my electric start, so I'll have that too, but having the kick start on the bike in my opinion, completes the picture of an old ironhead harley.
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  #10  
Old 19th August 2010
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This is relevant to my interests. Mainly I just want a backup should the starter fail. Plus its cool.
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