When I took apart my 4 spd I notiuced the C-clip sitting on the bottom of the cover and it was bowed....see pic 1.

I am reassembling the cover and found that there is not enough space for the retainer and that is why it was bowed. A standard 3/8 clip will not fit on the end, there is not enough space. Is there a special C-clip for this? I believe all is original parts. I bought a new revtech 4 spd 10 years ago and the clutch lever shaft just pulled out...they do not even use the clips anymore...

 

you will find that the washer needs to be thinned a bit, you can do it with same paper on a flat table = if you belt sand it it wont be straight - we use a magnetic surface grinder and hand measure and fit

 

I can do that. I think I might mount the cover on my overhead mill and resurface the bottom mount boss to be flat. I would guess they lower busing was not pressed in all the way....here is a pic of me fixing the sloppy machining of the countersunk cover hole....if guys need machining, PM me....

 

cool its always easyer to explain stuff to a guy who can in fact fix things

always change the large selector springs in the rotator when you have it in your hand

 

my problem is I have never owned a stock shovelhead and have no idea of how the equipment was originally designed or setup. the manuals are nice but are written for someone that has a stock bike in front of them...not pieces in buckets.

 

if i dont know actually how to fix or a way to do something i will tell you, almost all the bikes i take on are or have come from buckets and or swap meets is would seem in the shop -

this one was a basket case and is now on display in the AMCA winners circle exibit at Motorcyclepedia in newburg NY museum

 

decided to just machine it...indexed to the bushing edge...15 minutes...fine now...