INSTALLATION FOR 3” ELECTRIC START FOR 1970-78 SHOVELHEAD
(Kit numbers EVO-10S, EVO-10ST, EVO-10SF, EVO-10STF)
KICK START:
(Kit numbers EVO-4S, EVO-4T, EVO-5S, EVO-5T,
EV-76-47S, EV-76-47T, EV-72-47)
NOTE: THIS DRIVE REQUIRES A STOCK 1991 UP STARTER. THIS KIT WAS DESIGNED AROUND A STOCK FX.
AFTER MARKET STARTERS WILL NOT FIT WITH A STOCK OIL TANK AND BATTERY BOX. A 1979 CLUTCH
RELEASE ARM WILL ALSO BE NEEDED, OEM # 37054-79, AND THIS ARM WILL NEED SLIGHT
MODIFICATIONS TO WORK. SEE INSTRUCTIONS BELOW.
Be sure to read the Warranty, Introduction, belt tracking and starter gear problems, alignment procedure and
disconnect battery.
1. Remove outer primary cover, chain or belt drive and inner primary.
2. Loosen transmission completely.
3. Modify stock oil tank support bracket by notching
it as illustrated at right. This will allow clearance to the
back side of the starter. (Fig. 1)
4. BE SURE BATTERY IS DISCONNECTED.
5. Install starter pinion gear, supplied with kit, onto
starter shaft. Apply red Loctite® and install starter bolt.
6. Install cables on to starter and place starter on
transmission for later installation.
7. The clutch release arm must be clearanced to
achieve maximum travel of the arm against the
starter. (Fig. 2)
Fig. 1 Fig. 2
Cut a notch in oil tank support bracket as pictured above
for clearance on the back side of the starter.
Grind side of arm to allow maximum travel against starter when
installed.
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8. Install motor plate and tighten bolts to motor and
transmission. Check clearances between transmission
plate and frame, (shim if necessary, plug fit). Torque
all bolts down to HD specifications. (Fig. 3)
Install motor plate, you can install hexagon extensions at this
time and check for proper movement of starter pinion gear.
Fig. 3
9. Check to be sure that mainshaft woodruff key fits
properly into the clutch hub slot. Turn mainshaft so
that the slot faces 9 o’clock for installation. Shim front
pulley if necessary then install front pulley, rear pulley
assembly and belt at the same time. Install engine nut
and stock HD hub nut with seal (not supplied with kit)
but do not tighten at this time.
(Fig. 4)
Install both pulleys and belt at the same time, check all
FIg. 4
clearances.
10. Rotate the motor by hand to be sure belt tracks straight and away from motor. Be sure that belt is not
dragging on any part of the motor plate. If installation is correct then remove engine and transmission nut, apply
red Loctite®, reinstall and torque to HD specifications.
11. Bolt starter to motor plate, grease starter housing bushing and install over starter gear. Tighten front bolt first
then lift up on housing while tightening rear bolt. This should allow proper alignment of starter gear.
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12. Install Quiet Clutch, 1-.120" (EDP-200) spline steel
first, then alternate fiber and steel ending with a
steel.Install pressure plate, springs and shoulder bolts.
To install shoulder bolts apply red Loctite® to a bolt and
install it one turn, go on to the next bolt with same
procedure until all 6 bolts are in place, then tighten
them all the way down until they bottom out. There is
no adjustment to the spring pressure, this is all
pre-determined with the length of the shoulder bolt
and exact dimensions of our pressure plate. (Fig. 5)
Our pressure plate, EPP-100, is supplied with 9 springs, ECS-100
and 9 bolts, ESB-100. It is not necessary to use more than 8
springs for a stock application. For larger motors it may be
necessary to use 8 or 9 springs.
EDP-200.120 thick steel then alternate fiber and steel ending
with a steel (clutch pack is 1-.120 steel, 7 fibers (ERCP-100), 7
Fig. 5
steels (ERCS-100))
13. Install the 4 hexagon extensions into motor plate, shim if necessary with washers supplied and mount side
guard with the 4 buttonhead allen bolts. Note: one hole is countersunk so that this bolt will not interfere with the
midshifter.
14. Clutch screw adjustment should be 3/4 to 1 turn loose from lightly seated. (Note when clutch is hot the
adjustment screw should not be seated). Tighten jam nut when adjustment is complete.
For 3" kick start kits using BDL clutch:
1. Follow steps 1, 2, 3, 5, 10, 11, 13, and 15 above.
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