OSKRG Research/Restoration Bulletin #7 Sportsters 57-79 Kick Starter Parts This research and restoration bulletin was created with input and assistance from members of the OSKRG. The report consolidates the best available information at the time of creation and may be updated or revised at a future date. If errors are identified, or there is additional information on the subject of this report that has not been included, please post comments, corrections or additions to http://harleykmodel.com in the “Forum”.
Transcript
OSKRG Research/Restoration Bulletin #7 Sportsters 57-79 Kick Starter Parts
This research and restoration bulletin was created with input and assistance from members of
the OSKRG. The report consolidates the best available information at the time of creation and
may be updated or revised at a future date. If errors are identified, or there is additional
information on the subject of this report that has not been included, please post comments,
corrections or additions to http://harleykmodel.com in the “Forum”.
Part Model Years 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
37755-57 Spacer, Clutch Sprocket (long)
57-67 XL, XLH, XLCH 68-70 XLCH
C H
C H
C H
37756-57 Spacer, Clutch Sprocket (short)
57-70 XL, XLH, XLCH
37755-71 Spacer, Clutch Sprocket (long)
71-Early 73 XLCH E 73
37756-71 Spacer, Clutch Sprocket (short)
71-Early 73 XLH, XLCH
E 73
37753-76 Spacer, Clutch Sprocket
67-* XLH 79-XL & XLS
L 75
37754-74 Spacer, Clutch Sprocket (long)
57-70 All Sportsters
37755-73 Spacer, Clutch Sprocket (long)
71-79 XLCH Late 73-Early 75 XLH
L 73
E 75
33432-57 Early Gear, Starter Ratchet
57-70 All Sportsters
33432-57A Gear, Starter Ratchet
57-71 All Sportsters
33432-57 Late Gear, Starter Ratchet
57-Early 73 E 73
33432-73 Gear, Starter Ratchet with Bushing
Late 73-* XLCH L 73
33442-57 Bushing, Starter Ratchet Gear
57-Early 73 All Sportsters
E 73
33442-57A Bushing, Starter Ratchet Gear
57-71 All Sportsters
33442-73 Bushing, Starter Ratchet Gear
Late 73-* XLCH L 73
33379-57 Starter ratchet
57-70 All Sportsters
33379-71 Starter ratchet
71- All Sportsters
33379-71A Starter ratchet
71-* All Sportsters
6469 Washer (For Starter Crank Gear Stop)
61-* All Sportsters
6802 Shim, Starter Crankshaft
54-* All Sportsters As Required
33109-54 Kick Starter Shaft Collar
57-63 All Sportsters
Part Model Years 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
33094-77A Crankshaft, Starter
77 to Early 79
33348-78 Gear, Starter Crank
77 to Early 79
33400-74
Starter ratchet & Ratchet Gear Kit
• 8215 Rivet
• 33379-57 Starter Ratchet
• 33432-73 Gear, Starter
with Bushing
• 37754-74 Spacer, Clutch
Sprocket
57-70 All Sportsters See the following page to read the HD Service Bulletin No. 618C that addresses the use of these kits for starter replacement.
33460-74
Starter Ratchet Gear Kit
• 33432-73 Gear, Starter
with Bushing
• 37755-73 Spacer, Clutch
Sprocket
71-* XLH, XLCH See the following page to read the HD Service Bulletin No. 618C that addresses the use of these kits for starter replacement.
How to interpret the Table:
If a part numbers “Year Square” (57-79) has color in it, it will work with any other part with the same year square that has color in it with the exception of Kits (I think?).
Green indicates it was the original PN for that model year. Red indicates it is a later version of the part that will work in place of the original part. Yellow indicates uncertainty, more
documentation needed.
Starter Ratchet Gear & Starter Ratchet Model Compatibility
Green Compatible Yellow Unknown Presently Red Not Compatible
Aftermarket Compatibility
My finding using Harley OEM Parts is stated to the left, I found that the early version of the ratchet gear with 18 teeth would only properly mesh with the 18-tooth ratchet plate. As seen with the above Eastern aftermarket parts this does not appear to be the case. Their “Kit” uses an 18-tooth ratchet gear with a 9-tooth ratchet plate. Notice the note on the label indicating the bushing will need to be honed.
Original 18 Tooth -57 Starter Ratchet (Small ID)
2nd Version 9 Tooth -57 Starter Ratchet (Small ID)
3rd Version 9 Tooth -57 Starter Ratchet (Big ID)
-71 Starter Ratchet 9 Tooth
-71A Starter Ratchet 9 Tooth
-57 Ratchet Gear (18 Tooth)
-57 Ratchet Gear (9 Tooth)
-57A Ratchet Gear (Teeth # Unknown)
-73 ratchet Gear (9 Tooth)
Comments about the XLH Kickstarter and Other Post 67 Sportster Issues
By Bob Evans
As we know all Sportsters were kick start only up to and including 1966. 1967 the electric start XL appeared and all XLH models left the factory with both push button and kick starting as a fail-safe it would appear. But the electric start Sportsters worked so well that the kick option was discontinued for 1968 XLH's. But the cases were still machined for a kicker shaft to be retrofitted thereafter. The kicker hole on 1968 and later XLH's was plugged by p/n 24577-68. So, for 1967 through 1969 there were two sets of Sportster crankcases and two separate frames for the XLCH and XLH. AMF took over H-D in the fall of 1968 and about the same time DOT, (Department of Transportation), was dictating changes for motorcycle manufacturers. Blending the two together, (AMF/H-D & DOT), changes would come to Harley Davidson. DOT, citing crash compiled statistics ordered ALL highway use cycles must have a front brake activated light switch. This is why 1969 XL's have this running change as well as front and rear fender side reflectors. For 1970 ALL highway use cycles are required to be able to have headlights remain on with the engine not running. For two reasons this was a no brainer for AMF/H-D; Great excuse to get rid of the rather expensive and complaint riddled magneto, and while they were at it AMF said why not 'communize' both XL models. So, for 1970 we have only one set of crankcases and one standard frame for two models. 1973 turn signals became required per DOT on ALL highway cycles. And finally, for 1975 standard left side shift and right-side braking was required. To me this is the strangest thing; DOT told the industry in 1969 that 1975 would be the year for standard shifting required. Yet H-D waited until the 1975 model year was at the doorstep to do the half assed right to left conversions on the Sportsters for 1975 & 1976 while at the same time completely redesigning the Sportster bottom end for the 1977 models with the shifter properly exiting the left side crankcase and changing to an untimed gyrator oil pump and mini sump based on XR750 developments from 1974. (Observe in your parts books that 1977 & later Sportster crankcase, oil pumps and shifter shaft parts are all 1975-part numbers!) So, through all of these years from 1970 forward any Sportster could be made a kick or electric start or both. This continued to and including 1980 as the cases were still machined with kicker shaft holes, even though kick start Sportsters, (so called XLCH's), were finished production in 1979. For 1981 the new Hitachi starter was introduced requiring a redesign of the left case half and the kick shaft hole was no more. In 1982 the new frame and rear engine mount were introduced further eliminating any possibility of a return of a kick starter on any Sportster. Regards, -Bob-
33348-57 Can be distinguished from the -78 gear by the relative position of the centerline through the square
shaft hole and round hole to the gear teeth. The line falls about 3 & ½ teeth to the left of the cam plate ramp. You can tell it from the -52A gear by the gears larger OD & it has a raised area on one side around the square hole.
33359-57 Starter Crank Gear Cam Plate
33359-57 You can distinguish the -57 cam plate from the -52 & -52A plates by the -57s larger size. You can tell it from
the -78-cam plate by the relative position of the closest rivet holes to the cam plates ramp. On the -57 the holes are in line with the edges of the ramps. They are not on the -78.
33348-78 Gear, Starter Crank
33348-78 You can
identify the -78 Crank Gear by the relative position of the centerline through the square and round hole to the cam plate ramp. For the -78 gear it is
about 1 & ½ teeth. For the -57 gear it is about 3 & ½ teeth.
33110-54 Kick Starter Shaft Thrust Plate
33094-57 Starter Crank Shaft
This Starter crankshaft can be identified by the 18 degree offset between the squared ends of the shaft and the 1.12” -54 Collar. What distinguishes it from the -52A K Model shaft is the squared end that holds the crank gear is about .42” rather than about .25” on the -52A.
Spacer Information from HD Service Bulletin No. 618C
73 PB Supplement Information showing factory dimensions of length for some spacers.
From the 74 Service Manual. The Late 73 & Later Spacer is the 37755-73. Note: I find it interesting that the 73 “Supplement”, the 74 Service Manual and the No. 618 Service Bulletin show different sizes.
37755-57 Spacer, Clutch Sprocket (Long)
37756-57 Spacer, Clutch Sprocket (Short)
37755-71 Spacer, Clutch Sprocket (Long)
37756-71 Spacer, Clutch Sprocket (Short)
37754-74 Spacer, Clutch Sprocket (Long)
37755-73 Spacer, Clutch Sprocket (Long)
37753-76 Spacer, Clutch Sprocket
Length=1.151” OD=1.628” Thickness=.223” ID=1.184” Spacer has No Flange
33432-57 Gear, Starter Ratchet
The original version of the 33432-57 Gear had 18 teeth, the later had 9. This Gear will work with all 3 versions of the -57 Starter Ratchet.
33432-57A Gear, Starter Ratchet
33432-57A I do not have a sample of this gear in hand to
dimension it but based on Parts Books and Service Bulletins I believe it to be dimensionally the same as the -57 gear with the only difference being its’ -57A bushing. Because of issues with the bushing it was recommended that it be replaced with the previous gear and bushing used, the 33432-57. HD Service Bulletin No. 618A dated August 25,
1972 States “ Kick starter clutch gear assembly, part No. 33432-57, with bronze bushing should be used exclusively for replacement instead of gear, part No. 33432-57A, which has a bronze plated steel bushing.” HD Service Bulletin No. 618B dated August 17, 1973 states “New parts, as a parts assembly only are reccomended for replacement in all 1971 to present XLCH engines. New parts cannot be interchanged with earlier parts individually, they must be used together. Note: old parts will no longer be sold when present stock is depleted.” The assembly of parts being referred to are the -73 kick starter gear, bushing and spacer. Note: I believe some or all of the 1971 bikes would have used a -71 starter ratchet. This ratchet has the small ID like the first and second versions of the -57 ratchet. The -73 starter gear and bushing will not fit it.
33432-73 Gear, Starter Ratchet with Bushing
33432-73 This Gear will only work with the later third version of the -57 Starter Ratchet.
3442-57 Bushing, Starter Ratchet Gear Version #1
Version #1 Bronze
Note: Measurements made by me on new and used parts.
33442-57 Bushing, Starter Ratchet Gear Version #2
Version #2 Has 3 holes rather than an”X”. Bronze
Note: Measurements made by me on new and used parts.
33442-57A Bushing, Starter Ratchet Gear Version #3
Version #3 Bronze plated steel bushing. Steel bushings were used in production during the 71 model season and are easily recognized by steel color on the outside surface. This 57A bushing had problems (see the Service Bulletin No. 618 that follows). If this bushing was to be replaced HD recommended it be with the -57 bushing. HD Service Bulletin No. 618A dated August 25, 1972
states “The recommended gear, part No. 33432-57 is listed in your 1972 Sportster parts catalog supplement. Also listed is the replacement bronze bushing for this gear, part No. 33442-57. However if this bushing is used to replace a steel bushing, it must be reamed or machined to 1.361 I.D. after pressing into gear. The amount of material to be removed from the inside diameter is approximately .020 in. Do not hone this material out because grinding particles will imbed into bronze material and wear out the clutch sprocket spacer.”
Image not of a -57A
bushing.
33442-73 Bushing, Starter Ratchet Gear
Note: Measurements made by me on new and used parts.
33379-57 Starter ratchet-Original Version, came out in 57.
33379-57 Transitioned from 18 to 9 teeth sometime after 57. When unclear at this time. The -73 Starter Ratchet Gear will NOT work with this
Ratchet. 33379-57 Starter ratchet-Second Version, came out sometime after 57.
This ratchet plate has only 9 teeth but is dimensionaly the same as the first version with 18 teeth. The -73 Starter Ratchet Gear will NOT
work with this Ratchet.
33379-57 Starter ratchet-Third Version, came out in 73?
33379-57 Have only observed this second version with 9 teeth. The -73 Starter Ratchet Gear will work with this Ratchet. Notice the ID of
this plate is larger.
33379-71 Starter ratchet
33379-71 I believe this part was used for all or most of 1971. Note that it has a smaller ID than the -71A.
ID = 1.51” Note: Measurements made by me on new and used parts.
33379-71A Starter ratchet
33379-71A I believe this part was used from 72 on. Note that it has the larger ID to accept the -73 starter gear
and bushing.
ID = 1.58” Note: Measurements made by me on new and used parts.
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