The one way starter clutch on my bike has got 2 cracks in it.Would it be safe to weld it or is new the only way to go? The problem is they are 200 pounds from Yamaha and trying to find a used one is like finding hens teeth
The starter clutch is made to close spec - it reies on the good finish of the outer drum to allow the rollers to slip when over-driven by the engine yet grip when cranked by the starter. It's doubtful you could weld it without ruining it IMO, but if it's knackered anyway what do you have to lose?
One thing - I had a GPZ600R with a worn one-way starter clutch. It engaged when the engine was running and trashed the starter motor.
if it has gone what do you have to lose put a shallow v in it weld and grind smooth then make a band to go round it to give it strength and tack it on if you have space to do that
it wont have to be real thick just strong enough to give it some support,
make a band weld up slightly small then heat up the band so it expands put it on and let it cool and it will tighten up as it cools then just tack it to make sure it cant move