1977 cam cover question
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6th Gear
Joined: Nov 2010
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From: new york
1977 cam cover question
my buddy bought a 77 ironhead a couple weeks ago it ran fine we went to start it and the battery was dead so we jumped it off my truck, as soon as we removed the jumpers it would die so i tested the reg and it wasnt getting juice from the generator so i tested it at the generator and nothing so we took the generator off my 71 ironhead to swap it when we took his off we noticed the nut and washer were missing so we pulled the cam case off found the washer and nut. problem is it went throught the generator gear and cracked the cam cover. ***my question is, it seems they only made this cover for late 76-78. whats the difference between older covers(71- early 76) and can we make any other year cover work because we cant find the 76-78 cover for less then $300 plus $100 for bushings. is there any other options? can a cast cover be fixed? thank you for any info you got
The 77 & 78 gearcase covers have a different crankcase breather fitting at the 6:00 position under the end of the generator. There may be other differences.
Replacing a gearcase cover is problematic. You cannot just replace the cover. You have to completely dismantle the engine, split the cases, and line ream the new bushings using the right side case and a special tool which is generally unavailable anywhere.
If you have a spare right side case from another engine it is acceptable to use that.
So it is the usual practice to find a good welder and have the cover repaired. The repair must not put the bushings out of alignment. It requires a very good welder who thoroughly understands the importance of clean when welding aluminum, and will not distort the part by even the tiniest amount.
I am not expert on this. I am merely passing on what i have learned from reading these forums over the years. You need to get info from someone who has actual experience.
Post a pic of the damage.
Replacing a gearcase cover is problematic. You cannot just replace the cover. You have to completely dismantle the engine, split the cases, and line ream the new bushings using the right side case and a special tool which is generally unavailable anywhere.
If you have a spare right side case from another engine it is acceptable to use that.
So it is the usual practice to find a good welder and have the cover repaired. The repair must not put the bushings out of alignment. It requires a very good welder who thoroughly understands the importance of clean when welding aluminum, and will not distort the part by even the tiniest amount.
I am not expert on this. I am merely passing on what i have learned from reading these forums over the years. You need to get info from someone who has actual experience.
Post a pic of the damage.
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JohnJohnson
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Oct 21, 2015 11:42 AM
