XLCH Kickstart Crank Gear Fit on Shaft ? - The Jockey Journal Board

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Old 02-15-2019, 02:27 PM   #1
whittiger650
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Cool XLCH Kickstart Crank Gear Fit on Shaft ?

I am installing a kickstarter setup on my 1970 XLH. The kicker components came from a 1963 XLCH.

Test fitting the components before assembly revealed some burs that I could readily see which were what I thought was contributing to what seems like a hard interference fit.

However, after deburring the crank gear and shaft edges, it's barely better. Should the crank gear be a sliding fit onto the shaft with no interference or is it normal to have to tap it on having an interference fit, which doesn't seem right to me ?
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Old 02-15-2019, 03:07 PM   #2
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Default Re: XLCH Kickstart Crank Gear Fit on Shaft ?

Yeah, that would be a tight fit, it should need to be knocked out with a mallet when removing.

When you get it fitted and check end play, rotate the shaft and check it in a few places.
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Old 02-15-2019, 04:34 PM   #3
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Cool Re: XLCH Kickstart Crank Gear Fit on Shaft ?

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Yeah, that would be a tight fit, it should need to be knocked out with a mallet when removing.
Thanks. Did you mean "should" be a tight fit, instead of "would" be a tight fit ?
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Old 02-15-2019, 05:02 PM   #4
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Default Re: XLCH Kickstart Crank Gear Fit on Shaft ?

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Originally Posted by whittiger650 View Post
Thanks. Did you mean "should" be a tight fit, instead of "would" be a tight fit ?

Erm, both...sorry, typing / remembering in an inarticulate hurry. That engineering application ‘would’ require a tight fit to ensure that the mating surfaces do not wear and get sloppy. (Thinks hard to make sure not spouting bollocks...oh yeah, remember this now...) You ‘should’ need to knock the two apart with a mallet or brass drift. Which you might need to do several times in the near future to get end play right. Tight is good.

More to this assembly than meets the eye.
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Old 02-16-2019, 06:41 AM   #5
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Cool Re: XLCH Kickstart Crank Gear Fit on Shaft ?

I appreciate your help. Now, time to put it together.
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Old 02-21-2019, 08:57 AM   #6
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Default Re: XLCH Kickstart Crank Gear Fit on Shaft ?

Be careful the clutch spacer and sleeve and possible gear from your 69 pieces are not correct for your year bike and big trouble could result. please do your research.
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Old 02-22-2019, 05:36 PM   #7
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Cool Re: XLCH Kickstart Crank Gear Fit on Shaft ?

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Be careful the clutch spacer and sleeve and possible gear from your 69 pieces are not correct for your year bike and big trouble could result. please do your research.

Yes, I did do the research. According to my parts book, 1963 parts in question are the same for the 1970 models.
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Old 03-06-2019, 10:58 PM   #8
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How did it turn out im very interested since im building a 70 xlh too my kicker gear slides right on the shaft not tight at all but doesnt have play if that makes sense
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Old 03-07-2019, 06:54 AM   #9
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Cool Re: XLCH Kickstart Crank Gear Fit on Shaft ?

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How did it turn out im very interested since im building a 70 xlh too my kicker gear slides right on the shaft not tight at all but doesnt have play if that makes sense

I got stalled by deciding to buy some special tools and waiting for the last one to get here in order to put the primary back together without using bodges and the extreme cold we have had lately.

So, I should be updating soon. I feel like my kicker gear should fit more easily like yours !
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Old 03-07-2019, 09:50 AM   #10
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Im stalled out too i need to fix the clutch basket chingadera and need the thimbles for the clutch springs ive slowly been gathering what i need since my electric kick start on the 70 has a lot of 1 year parts kinda hetes what im messing with i have 2 clutch set ups 1 for the 70 and 1 for a newer wet clutch set up that im not using shovithead hooked up the stock parts for mine and steered me in the right direction (super miss that guy) but everyone here lent me a hand and helped me get my tranny shimmed right mostly through direct messages
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