1973 Hare Scrambler clutch cover

[Andreas Piepke]

After Al Buehner cleared this up it is clear that there is no easy solution for converting an early engine with a 14 mm kick starter shaft into one accepting a 17 mm shaft.

Here my solution. The left engine case is aligned with the existing hole using a micrometer.
http://s1341.photobucket.com/user/andreas_g_piepke/media/Penton/100_3166_zps871230dd.jpg.html?sort=3&o=2

The hole was then opened on a mill and reamed to give it a smooth surface for the shaft. A recess machined into the kick starter hole to accept the new alignment bushing, which was on the starter shaft in the original configuration. Measurement of the starter hole in the clutch cover, using again a micrometer and the mill, showed that it is out of round. This is to be expected for a shaft rotating directly in the magnesium without hardened bushing.
http://s1341.photobucket.com/user/andreas_g_piepke/media/Penton/100_3175_zpsa1dcc3bc.jpg.html?sort=3&o=0

After that the cover fits well, the kick starter shaft fits and rotates easily in the well aligned openings.
http://s1341.photobucket.com/user/andreas_g_piepke/media/Penton/100_3168_zps8116acd1.jpg.html?sort=3&o=1

As far as I understand an o-ring on the kick starter shaft provides the oil seal. How is it held in place? Is there a bushing on the shaft behind the kick starter lever?

Cheers

Andreas

[ALB]

A plastic bushing goes between the o-ring and the kick start lever. The kick start lever pressing against the bushing holds the o-ring in place.
I have these in stock or you can make your own.

Alan Buehner