There is no relative rotation between pilot on input shaft and pilot hole in crankshaft BUT The input shaft pilot should be a close fit because it keeps the rear of the input shaft properly aligned.  Don't wallow it out indiscriminately.  A small groove in one side (from the dremmel operation) will not hurt.

 

Tracy

 

 The next chore was the removal of the pilot bearing. We
had tried removal from several approaches without success.. The Harbor
Freight pilot bearing puller is a smidge too large to go into the
bearing hole... finally I re-read the RD1-B install manual and it
mentioned that a dremel has been used in the past for stubborn ones. I ended up  extracting the individual needles with a scalpel and
needlenose pliers, collapsed the inner race and yanked it out, then
ended up using a dremel to gouge the outer race, then collapsed IT as
well.. Infortunately this gouged the inside of the bearing channel  in
the process, so I drum sanded rough spots until it was finger smooth.
The PSRU pilot shaft was able to fit in without difficulty.
 My understanding of the bearing removal is that it doesn't have to be smooth, just give clearance for the pilot shaft since the shaft does not revolve in the bearing hole. Correct? I had a slight drag when the re-drive was rotated so dremelled the hole with a stone to give more clearance. What I don't understand is, why would there appear to be runout at the pilot shaft of the RD-1?

Wendell