If we are looking for a replacement starter clutches, I thought it might be of use to have the dimensions for reference. Outside diameter ( Inside of Sprocket) 2.614 inch ( 66.4mm ) Inside diameter ( Starter gear hub ) 1.955 ( 49.66mm) Width .730 ( 18.54mm ) There is enough material in my opinion to add up to 5mm O.D. By boring the sprocket hub or 5mm smaller I.D. by turning down the starter gear and possibly another 2 mm of width if needed. I think both of these parts are thru hardened ( heat treated ) if they are only case hardened ( Shallow hardness on the surface ) would require re case hardening and probably not worth the trouble to do then. If replacements are found close to original dimensions or with one or two matching dimensions then this could be an affordable repair, especially if we are remachining worn surfaces. Also I.D. or O.D. could be sleeved if needed. Parts would need to be machined with a cylindrical grinder as was done originally or done in a lathe with a tool post grinder because of their hardness. I'm sure this would be less expense that getting a small batch made. I am also curious if the failures mentioned are the early version shown in Suzuki's technical bulletin "RE-6 " ( listed under resources "service bulletins" on this site ) used before engine # RE5-12054
There is enough material in my opinion to add up to 5mm O.D. By boring the sprocket hub or 5mm smaller I.D. by turning down the starter gear and possibly another 2 mm of width if needed. I think both of these parts are thru hardened ( heat treated )
That's good observation & the material can be removed properly with the right equipment. You would need to find a machine shop with an O.D. & I.D. precision grinder along someone that knows what they are doing
There are several Sprag Clutches shown, one or two of them look like our wayward One Way Clutch. It's Suzuki so there might be a chance that they are using a supplier that makes a Sprag Clutch that would be what we are looking for.