by thefrenchowl » Tue May 05, 2020 6:29 pm
Peter,
Look at it this way:
Any Sportster post 67 with a lecky starter has had its primary drive moved out to the left by about 250 thou to make room for the ring gear.
So, the primary drive of these gear boxes won't fit K, KH or up to 70 XLCH no matter what you do to them...
To the trained eyes, it is easy to see this offset on both the engine sprocket, clutch gear, clutch hub and obviously clutch basket.
Don't try to mix and match parts fron different gear boxes if you don't know these gearboxes well, it will end up in tears.
Try to find a full gearbox assembled on its trap door from 54/70 KH/XLCH or 54/66 KH/XLH
These as a full unit will fit in the KH cases apart from the Sportster trap door.
Once you have a full tranny on a door, you just have to swap the sportster trap door for your own KH trap door, hey presto, do the end play washers... job done...
There might still be an issue with the speedo drive gear ratios between KH and XL, I've never used that piece of trash cause of case reinforcing, so if you really want the speedo drive, somebody else will have to chime in with more details...
And forget the horror stories about weak gears in KH boxes.... All the KH and later boxes are fragile, but nothing to do with the gears...
The culprit is the speedo drive, and that, up to the Kobaya forks, that's 1973...
Patrick