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Thread: Check Your Starter Bushings. A pictorial of a case repair.

  1. #1
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    Default Check Your Starter Bushings. A pictorial of a case repair.

    Here's a case that went too long. Blew out the bushing and ate the case.
    Remarkably, it still started.
    The following is what is involved in salvaging a case that was ruined by a lack of maintenance.

    Blown out bore...
    Click image for larger version. 

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    The cylinder base surface was chosen to base off of for straightness,
    and the clutch slave cylinder bore was used as a zero datum,
    then the location of the bore was measured in relation to the datum.
    Fortunately there was enough of the bore remaining below the damaged are to get a good reading from.

    Click image for larger version. 

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  3. #2
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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    The damaged are was TIG welded to replace the missing material.
    This casting is pretty good quality allow, it took the filler rod easily.

    Click image for larger version. 

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    Last edited by roamer; 01-11-2020 at 05:22 PM.

  4. #3
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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    A lot of castings are not so good, and are difficult to get them to take filler alloy.

    Click image for larger version. 

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    Back into the macining center for some clean up and decking.
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    A rough bore to verify the location..
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    Last edited by roamer; 01-11-2020 at 05:22 PM.

  5. #4
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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    Then the bore was finished up to final dimension and a new bushing installed.

    Click image for larger version. 

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  6. #5
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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    What kind of interval would you recommend checking the bushings?
    Good job on the repair!
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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    This case belongs to a friend, not sure on the hours of this one.
    He just bought it used. There appeared to be remnants of some jb weld in the bore.
    So I'm guessing it had some time on it
    Mine were toast at 40 hours when I took it apart to clean and lube it,
    so I would recommend 30-35 hours inspect and add grease.

  8. #7

    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    Good job. This verifies, for me what I have been saying, that the bushings are not the cranking problem of the Freeride. It still cranked. It's not a weak starter. It's the timing. Since this bike will run backwards, we realize that the firing is right at top dead center. There is a point on a bicycle pedal that you can stand on the upward pedal if you have no initial movement. When it encounters an attempt to crank when the piston is 100% top dead center, the starter gets fried due to a direct ground. Once fried, it never has adequate power again. Of the 7 starters that I have fried, they all smell just like a house fire.

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    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    Quote Originally Posted by 1gr8bldr View Post
    Of the 7 starters that I have fried, they all smell just like a house fire.
    I think you should preface that statement with something about a hi compression head, no?
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  10. #9

    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    Quote Originally Posted by roamer View Post
    I think you should preface that statement with something about a hi compression head, no?
    I fried 2 before the high comp head. And 1 with the 300 head. So, the hi comp head is twice as bad, but the cold multiplied it also.

  11. #10

    Default Re: Check Your Starter Bushings. A pictorial of a case repair.

    The small hole seen in the pic, mine has this as well. It looks like a crude oil passage, and, looks like a casting issue at the same time. I assume it's supposed to be there?

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