Replacing starter cover bushings 33288-37

[panhead_kicker]

I have pressed in new 33288-37 bushings on my repaired starter cover. Does any one know what size reamer should be used for proper starter crank shaft fit?

repaired_starter_cover.JPG

[Robert Luland]

3/4"

[Panacea]

Have you checked the kicker for wear, or are you replacing it with new?

[panhead_kicker]

Have you checked the kicker for wear, or are you replacing it with new?

Good point, I had a used/broken starter shaft inserted and it was binding by hand/extremely tight. I will have to get a new shaft which I assume will be even larger in diameter, if anything. Bad assumption? I believe the old shaft to be OEM. New OEM shafts seem to be hard to come by so a decent aftermarket shaft is in my future.
Regardless, all things being equal I should have to ream to the 3/4" as Bob provided to obtain a proper fit, correct?

[Robert Luland]

Use a adjustable reamer that long enough to do both bushings at once. You want that fit to shaft to be thight. It will lossen up in no time under normal use. Bob L

[Bosheff]

Wait til ya git the shaft yer gonna use in yer hands before ya go for the final fit. Better safe than sorry....bosheff

[Cotten]

Panhead-Kicker!

A mildly worn shaft can be fitted if your new bushings are sufficiently under-sized, and the shaft's high-spot next to the nut is dressed down to less or the same as the worn portion.

Often when a new shaft is a squeak-fit new bushings, you may find that simply scrapeing the high spots will provide clearance, particularly if the tightness is due to weld repair distortion. One clue would be if it fits the inside end of the bore.

But most pro shops would just slide it a few strokes on their Sunnen until it was perfect, with a cross-hatch too.

SUNNEN.jpg

....Cotten

[panhead_kicker]

Panhead-Kicker!

A mildly worn shaft...

Unfortunately, my shaft suffers from a different kind of wear. I think this shaft has seen its last kick! (and I was the one kicking it...)

well_used_starter_shaft.JPG

[Panacea]

The last time I re-built a kicker I wanted to save the one piece arm, which was worn. I found a guy who (at the time) specialized in knuckle head repair, he put the arm in a big lathe and took it down to where the shaft was all one size. As I recall he also made some new oversize bushings to work with the new smaller arm size. He also worked on the tranny at the same time,installing an oversize MDG bearing race, since the old one was loose in the case and looked like someone had tried holding it in place with a couple stakes. The weird part was after I began running the new re-build I found the kicker was leaking oil, so I took it apart and found the guy had forgot the seal that goes between the two bushings in the kicker cover. Must have been a Monday...Mike

[Sir_Rat]

Any chance to have the chewed up end welded up and re-ground? Or take the original to a machine shop and have em make you a new one. JMHO

Aloha....Mike

[59Panman]

Isn't there also a modification to fill the voids surrounding bushing area material with weld to support the case from cracking? I can't remember where I saw this? Maybe on Matt Olsen's site?

[panhead_kicker]

Any chance to have the chewed up end welded up and re-ground?

I bet its a hardened steel. I'm probably better off with a new one of these. I think Jims make an expensive one...

Isn't there also a modification to fill the voids surrounding bushing area material with weld to support the case from cracking? I can't remember where I saw this? Maybe on Matt Olsen's site

I just dug up the kicker cover fix on Matt Olsens site. They milled out the cracks, and then built it back up with pure weld. Mine was milled out to bottom of cracks, and a slab of round aluminum stock welded on. Then bored. End result LOOKs similiar to Matt Olsens. I hope it holds up well. Government work. It good to have friends!<grin>
Thanks for the tips on the bushings everyone.

[Panacea]

I guess it looks like you have a swingarm bike but here is a nice one piece arm...http://cgi.ebay.com/ebaymotors/Kick-Sta ... 563b04c50f" onclick="window.open(this.href);return false;