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Strengthening of starter support.
On my motorbike, the support for 405-Fixed Hanger and 134-Shaft, Starter Assy, which is part of 105 Reinforcement, Side LH, was broken. I know at least one other motorbike where this happened. The support is box-like shaped and open at the bottom. While starting the engine, quite some force is exerted on the support, leading to cracks in or breaking of the aluminium casting, resulting in the teeth mesh of the Pedal Segment Assy and 621 Pinion, Starter to be incorrect. On my m.c. the support was welded before and cracked again. The support can be strengthened by
running a long 5/16” bolt from left to right through the ‘box’. To prevent the
box from being crushed, a hollow stud is fitted inside. As the stud has to be
tilted to be put in place, it must be shorter than the inside dimension of the
box from wall to wall. The clearance can be compensated by the horseshoe shaped
washer that can be seen on the pictures. NB! While assembling 4-Cross Shaft Assy The nut appeared to be too thick; 406-Chain Guard was in the way. The bolt and nut was replaced by a flat headed bolt, with the head at the inside and the nut at the left outside. This fitted perfectly, as there was just enough room for the flat head. In checking
Drawing 100-Frame Assembly, I found that the support part I just made should
have been there as Part Number 178-Distance Piece, Foot Starter. |