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I had a 1993-earlier Delkron inner primary for my 1988 FXR I'm going to convert to the later transmission. My 1994 FXLR had a cracked inner primary so I bolted on the Delkron (after a bunch of grind/try/grind to fit a 25T trans pulley I got cheap and want to try for giggles).
Turns out that 1993 and 1994 starter jackshaft hole bores are different because the starter jackshaft was redesigned and the pinion tooth count is different too so I turned a bushing to make the 1994 parts work in the older style primary. I didn't expect them not to match where the large starter jackshaft coupling sits since I wasn't familiar with the jackshaft year differences. This solution beat ordering a special order 1994 Delkron inner primary, involves no harm to the primary, and you can go back to a 1993-size bushing if you ever need or want to for some reason.
I knocked out the included starter bushing from the Delkron with a punch as it was too shallow for my pullers to grab. If I were replacing the stock thin bushing I'd do the same trick as is done with tapered race mag wheels and grind a two round-bottom notches 180-degrees apart behind the bushing to get a much better bite with a punch when the next removal time comes. My custom bushing has thicker walls so case notching isn't required.
Found an old bronze bushing at my buds machine shop (save the big 'uns because you can make 'em into little 'uns) and made a nice thick adapter bushing.
Delkron starter bushing bore in primary inside diameter was 1.657"
Coupling diameter was 1.370". Mine's a bit worn and what's not worn is lightly corroded so measure yours.
Stock inner primary starter bushing thickness = .496" so I turned new one to .500 even for convenience.
Turned bushing outside diameter to 1.658 then polished down with emery cloth to get half a thousandth interference fit. (Emery cloth cuts quickly so if you are new to turning bushings be aware you can ruin a part easily!)
Bored bushing ID to 1.373" (in the "loose" fit range) since the stock fit was rather loose and I didn't want the new bush to bind the coupling.
Installed bushing by tapping it into primary with my UHMW-faced hammer. Don't bash brass or bronze with steel. Bushing drivers are nice but given the shallow depth I didn't bother making one.
Placed clutch basket on transmission shaft then engaged starter (without power, safety first!) by using my pushbutton 'noid cap. Pinion gear engages as it should. If you lack a pushbutton noid cap you can remove the stock end cap then push the noid in with a plastic screwdriver handle. Inspect your contacts if you have the cap off.
The 1993-style Delkron primary is plentiful so you can hunt the best price vs a special order 1994-up primary. One-click order and done.
The other interesting bit is that if you want to use the 1994 and later primary drive setup on a 1993 and earlier stock Harley with the same style starter you can just make the bushing and have at it if you have the later jackshaft kit and starter motor or otherwise sort out the jackshaft bolt thread differences.
I defer to the primary drive ratio gurus on the best ratio and parts combo but making a simple sleeve bushing beat having to hunt or wait for an inner primary and you don't have to remove the primary to remove the old bushing and install the new one. It's an easy job.
As with any such machining measure YOUR parts first then make the bushing accordingly. You can cut to "metal positive" before hitting my dimensions then final machine to yours.
There may be a standard bushing close enough to these dimensions to modify, or perhaps a matchup in MSC or McMaster-Carr but this was free, easy and fast.
Turns out that 1993 and 1994 starter jackshaft hole bores are different because the starter jackshaft was redesigned and the pinion tooth count is different too so I turned a bushing to make the 1994 parts work in the older style primary. I didn't expect them not to match where the large starter jackshaft coupling sits since I wasn't familiar with the jackshaft year differences. This solution beat ordering a special order 1994 Delkron inner primary, involves no harm to the primary, and you can go back to a 1993-size bushing if you ever need or want to for some reason.
I knocked out the included starter bushing from the Delkron with a punch as it was too shallow for my pullers to grab. If I were replacing the stock thin bushing I'd do the same trick as is done with tapered race mag wheels and grind a two round-bottom notches 180-degrees apart behind the bushing to get a much better bite with a punch when the next removal time comes. My custom bushing has thicker walls so case notching isn't required.
Found an old bronze bushing at my buds machine shop (save the big 'uns because you can make 'em into little 'uns) and made a nice thick adapter bushing.
Delkron starter bushing bore in primary inside diameter was 1.657"
Coupling diameter was 1.370". Mine's a bit worn and what's not worn is lightly corroded so measure yours.
Stock inner primary starter bushing thickness = .496" so I turned new one to .500 even for convenience.
Turned bushing outside diameter to 1.658 then polished down with emery cloth to get half a thousandth interference fit. (Emery cloth cuts quickly so if you are new to turning bushings be aware you can ruin a part easily!)
Bored bushing ID to 1.373" (in the "loose" fit range) since the stock fit was rather loose and I didn't want the new bush to bind the coupling.
Installed bushing by tapping it into primary with my UHMW-faced hammer. Don't bash brass or bronze with steel. Bushing drivers are nice but given the shallow depth I didn't bother making one.
Placed clutch basket on transmission shaft then engaged starter (without power, safety first!) by using my pushbutton 'noid cap. Pinion gear engages as it should. If you lack a pushbutton noid cap you can remove the stock end cap then push the noid in with a plastic screwdriver handle. Inspect your contacts if you have the cap off.
The 1993-style Delkron primary is plentiful so you can hunt the best price vs a special order 1994-up primary. One-click order and done.
The other interesting bit is that if you want to use the 1994 and later primary drive setup on a 1993 and earlier stock Harley with the same style starter you can just make the bushing and have at it if you have the later jackshaft kit and starter motor or otherwise sort out the jackshaft bolt thread differences.
I defer to the primary drive ratio gurus on the best ratio and parts combo but making a simple sleeve bushing beat having to hunt or wait for an inner primary and you don't have to remove the primary to remove the old bushing and install the new one. It's an easy job.
As with any such machining measure YOUR parts first then make the bushing accordingly. You can cut to "metal positive" before hitting my dimensions then final machine to yours.
There may be a standard bushing close enough to these dimensions to modify, or perhaps a matchup in MSC or McMaster-Carr but this was free, easy and fast.
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