Skinnychopper's E-Starter Knucklehead Hack
There’s Harley riders beyond a certain age
whose enthusiasm for kick starting their hogs has, let’s say, seen better days. Ruining the looks of their lovingly cared for two wheeled treasures by some cobbled together amateur electric starter system isn’t an option either for them. If you followed us this far, maybe you’re the kind of guy we developed the Cannonball Stealth Starter system for, proven over the years with many miles on the road in places as far away as Cuba. The number of our systems out there in daily operation show us that there is a profound need for an electric start solution for vintage swing arm or rigid Harleys, answering the question: "Will I have to give up my Harley – or my knee?"
None of the above, said the gentlemen of Skinny Choppers (not for the first time), solving a few complications on the way on Jim’s personal bike. As the system works through the kick starter drive, neutral MUST be engaged – or the bike would be pushed along by the starter motor; disengaging the clutch won’t help. Which wouldn’t be great on the gearbox, the bike, or innocent bystanders. Now, how do you detect neutral on a Knucklehead gearbox of 1945 vintage, when neutral positions (and neutral switches) hadn't been invented yet in Milwaukee?
"Skinny Choppers' solution is elegant, efficient, and safe.
In their words: "So, we had to modify the box lid. This involved drilling a hole in the casing (the AMCA is raising an eyebrow) approx on the seam of the casting to fit a neutral switch lining up with the drive gear. Then, we swapped out the original shifter drum drive gear for a ratchet top gear which has the neutral slot *. Fitted a neutral light on the dash and wired the starter button through the neutral switch for safety reasons." This last bit is highly recommended: no neutral, no starter action. Brilliant.
Some mods of lesser involvement were also implemented on this bike: they didn’t fit a dent plate, just cut the fender short and fitted a vintage mudflap. Works great! Also, the rear exhaust pipe was gently modified to clear the nuts of the kicker cover. As usual, Skinny Choppers took many pictures to show the way round this ambitious modification. If you’re in doubt about anything however, better contact service@wwag.com BEFORE doing anything rash."
* The shifter drum drive gear had no slot for neutral, because this is a hand shift gearbox. Neutral is defined by the shifter gate on the tank. So they went and changed it for a later year foot shift drive gear which has the slot: W&W part number 74-029.
Finally, the gentlemen of Skinny Chopper want to point out that a Cannonball Starter makes Harleys with tank shifters much more street-friendly. In case the bike stalls due to awkward circumstances, pressing the starter button saves you from embarrassing moments.
Contact:
Vintage Harley Davidsons, Engine & Gearbox Rebuilds
Service & Repair work
Pateley Bridge, North Yorkshire, GB
Appointments only.
mobile +44 (0)7595 020 984
email: info@skinnychoppers.com
Instagram: @skinnychoppers
