Blink
Over the past year, I have had problems replacing air-cooled starter motors, part #0E9323. The aluminum housing on the new ones have very slight differences that don't seem to allow the bolt holes to line up.  Anyone else having similar problems?  If so, any solutions?
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kmarotta
The best solution I have found is to have the original starter rebuilt by a local starter alternator repair shop if you have one available. Otherwise, if you do a search for part #0E9323, you will see multiple variations, the correct ones are out there, just be sure to get the correct one. There is a definite difference in size of the bendix drive (number of teeth and the end housing itself) used in some of the older air cooled Generac generators. It has been my experience that if you order from Generac, they send the newest variant even when supplied with the unit and engine serial numbers.
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ohmslaw
A year ago I spent an hour and a half  doing a starter on an air cooled unit . Generac has a bulletin out now on the starter replacement. Heat shield issue.
SIB18-07-AAC
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Ron Goldstein Rongold
How about posting that bulletin for those of us who don't have access to it.

RON
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BrianMartin
All it says is to loosen the 10 mm bolt for the heat shield closest to the starter motor mount, pull the shield away carefully to make room for the motor, and tighten the bolt back up.
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MacL
I had a starter that was like that the other day.  Thought it was just an idiosyncrasy of that particular generator (something was bent, i.e.), but I got it in there.  If you take your fingers and press the heat shield hard toward the engine, no need to loosen a bolt, that will let you get the bolts started.

Generac Bulletins are often confidential and disclosure is forbidden, as this one is.  
State your problem, not your diagnosis.
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Geoff Z
I just went through this exact scenario with a customer recently. We put the old housing on the new starter. Problem solved.
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nrp3
I haven’t changed a starter in other than an 8kw in a while.  I read through this the other day and didn’t give much thought.  Had to replace one of those on a 530, what a pain the ass. I like Geoff’s idea. Think I’ll try swapping the housing next time.  
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Blink
I went back out today to attempt the same starter replacement, this time following the SIB. After two hours, I gave up and went to Geoff's solution. It took me 5min to swap housings. I will NEVER attempt another starter replacement again without swapping housings first.
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Geoff Z
So glad to hear it worked for you too. What a mess I was in. I had boxes of starters open across my office taking measurements and comparing. Peddler jumped in and was offering input. I had never ran into this before. I met up with the customer. We just put them side by side and stared and measured from every different direction. We decided what do we have to loose. I was so pleased when the housing swap worked. Get out of jail free card!!
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nrp3
I’ll probably save the front from the one I removed before I recycle it. 
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Ron Goldstein Rongold
The only problem with re-using the starter drive housing (nose) is that it usually has a brass bushing in it (automotive ones do--Generac--don't know--never saw one). If the bushing is worn out, the armature will have an excessive amount of side play in it and could make the starter motor drag. My experience with this is from Delco automotive starters as I owned 3 auto repair shops from 1970-2015 until I retired. I wonder if bushings are available for the Generac starter (looks like it is an older Delco design starter). Most auto parts stores carry bushings for Delco starters---I wonder if the Generac starter has the same size armature shaft as older Delco starters???  The bushing is easy to replace--Find the proper size socket and put an extension on it and drive the old one out and new one in.
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Wireform
The only problem with re-using the starter drive housing (nose) is that it usually has a brass bushing in it (automotive ones do--Generac--don't know--never saw one). If the bushing is worn out, the armature will have an excessive amount of side play in it and could make the starter motor drag. My experience with this is from Delco automotive starters as I owned 3 auto repair shops from 1970-2015 until I retired. I wonder if bushings are available for the Generac starter (looks like it is an older Delco design starter). Most auto parts stores carry bushings for Delco starters---I wonder if the Generac starter has the same size armature shaft as older Delco starters???  The bushing is easy to replace--Find the proper size socket and put an extension on it and drive the old one out and new one in.
I would Say if there is in fact a bronze bushing it's most probably a non issue in this starter and isn't worn out with play. You're talking automobiles, and generators get relatively many fewer starts. The starter issues on generators are not due to thousands of starts but rather a condition that burns them out.  
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78buckshot
Depending on the model of generator, some do, some don't.
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