Hi all, I've posted this also on the Evo page but was recommended to post here also. Feedback so far is "yes there's slack but it's normal and stick with the original thinner bolt".

I have a 1992 FXDC Dyna 60k miles, and as far as I am aware it is pretty standard in the engine and transmission dept….at least I haven’t change anything.

A couple of weeks ago there was a crunching sound in my primary, literary as I pulled p to my house. I opened her up and sure enough the Jackshaft starter bolt had come unscrewed ands the lock washer was broken. Everything else appears to be fine so I figured it’s a simple replacement.

I ordered a replacement which was the “Spyke Bolt/Screw kit Item № 13-798” for Big Twins 1989-1993, length: 132 mm; thread: 1/4”-20.

When I try and replace the parts it turns out the new bolt and washers are much fatter than my original and the thread is different. Mine is a lot thinner. The new bolt head is 10mm and 65mm thick shaft and my original is 8mm bolt head and the shaft is 5mm thick.

I tried using their washers and lock nuts with my bolt as it wasn’t broken but when I tightened it there was a lot of slack/movement and to be honest when I put the tab into the Jackshaft there was so much movement that I don’t think it


Tab in the groove

Tab easily comes out of the groove

would stay there for a minute. You can see in the photos and video. It feels like there should be a sleeve in there?

So….any idea whether my original thinner bolts is “original? And more importantly should there be this much slack in the bolt? It doesn't seem to make sense to have a tab/notch set up which is likely to not stay in the notch!

Sadly I cannot afford to buy an aftermarket system which might be better.
Attached Files
File Type: mp4

IMG_8324.MP4 (6.21 MB, 2 views)

 

Do you have the pert number for the OEM bolt? Once you have the part number a little searching should tell what size bolt it should be.

 

Thanks Vic, the part no. is 4325 and the measurements I'm getting would match my original "thinner" bolt (which has worked fine since I bought the bike 5 years ago, until now where the locking tab washer broke) my concern was also about the amount of movement it has but I'm guessing as it did somehow work before then that would the way it's supposed to fit?

 

Thanks Vic, I had a look online and the OEM 4358A which is for a 1994 and upwards model is actually what i have on my bike!

This problem has been solved in the Evo Post version. Basically the PO had changed the starter or jackshaft to a 1994 and onward one so the new part I ordered was correct for a 1992 model but too big for the jackshaft I actually have. Below is a quote from Yankee Dog member which correctly sums it up.
"The replacement locking washer tab and bolt is the wrong one for your set up (as you already know). The inner diameter of that locking washer tab is bigger to accommodate the larger diameter bolt (the wrong bolt). When you put the locking washer on the other original thinner bolt, there is too much play and the locking tab is not locking. You need the locking tab and sealing washer that matches your smaller diameter bolt. Order the locking tab and sealing washer for a 1994 model year."
Thanks

 

Glad you got it straightened out. I can't ever remember hearing of a jackshaft but I know bolts lol. Then again I never owned a Evo until last month. PO must not have used locktite LOL. The only starter issue I ever had was the starter clutch on my 08 Ultra. PO must not have used locktite