You're right, as you say as far on as it will go. Then just tighten the centre bolt good and tight, if there is a torque figure I don't recall ever seeing it.
If you're a real worrier just a small spot of Loctite on the bolt will let you sleep better at night but I've never had one come loose myself.
Magneto Question
But Wait, There's More - so I found a bolt of the correct size to fit the generator hole, and I have the generator all the way on the shaft - but when I tighten that center bolt, the whole setup won't spin - loosen the generator bolt, the crankshaft will spin; TIGHTEN the bolt, it locks up.
I think I'm missing something very basic here, but I don't know what...is the generator bolt supposed to be somewhat loose? I wouldn't think so...how long is that bolt supposed to be? Is that a factor?
Magneto,Can you tell where it is fouling, for instance is the starter clutch pushing against the sprocket or the oil seal.
Try leaving the starter motor off and see if the starter sprocket will turn anti-clockwise when the rotor and clutch are in place without trying to turn the crank, it should. The only other obvious? thing that comes to mind is that the rotor isn't seated properly on the crank / keyway and that when you tighten it up it is somehow tilting over and jamming the rotor inside the stator. Even this doesn't seem very likely. Try leaving out the woodruff key as a temporary measure and see if that makes any difference to things. I don't think the length of the bolt is an issue here, too long and it would simply bottom out in the threads without pulling the rotor into place, too short and it would simply engage on a few less threads, hardly ideal but no big deal. A while back there was a similar thread which I think identified different designs / sizes of starter sprocket as being an issue, I can't remember the specifics but I had always assumed all sprockets to be interchangeable, perhaps not? Let us know what you find.
(Sigh) Ok, I'm an idiot...bear in mind I had the case apart and replaced all the seals, including the MAIN seals...
To make a long story short, the Starter clutch SPROCKET still had the old main seal still on it, and I didn't even think about it until I started to write down exactly what I was doing...and what I was doing was tightening the OLD seal ON TOP OF the new seal! Tighten the bolt, the OLD seal tightens on the NEW seal and prevents it from turning. I popped off the OLD seal and the sprocket it fit perfectly into the NEW seal, and now my starter clutch works again. I'm STILL shaking my head. In the words of a famous American comedian, "Here's your sign"... So, 'SOLVED'. Duh... Starter sprocketMust say that I admire your honesty, I haven't heard of anyone doing THAT before, or at least admitting to it but others have done worse I'm sure!
Glad to hear that it's all looking good now.
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