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.
The box is pretty full and hence inaccessible, so the correct sequence of fitting bolts and nuts has to be used. 
First 621 Pinion, Starter has to be adjusted and the nut has to be secured (see ‘Starter Assy’ under section 6-Engine). Then the bolt and nut for 405 Fixed hanger must be tightened. The bolt has to be shortened, to create space for the strengthening bolt. Last the strengthening bolt with hollow stud has to be fitted.
The photograph shows a flat part on the stud; this is to make room for a previous weld of a crack.

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.
A photograph with dimensions of 178-Distance Piece, Foot Starter is wanted.