Hey,
First off let me say I am new here and this is my first post.

I have a 1998 Sportster 1200 Sport. It has 23k miles on it.
I just did a complete top end rebuild with new 10.5 to 1 wiseco pistons, new hd lifter tappets.

Well here's the deal, before I started this rebuild I had a clicking/rubbing noise coming out of the primary side of the motor. I took the clutch basket off. It turns out that the backside of the starter ring is rubbing the shifter assembly. It actually wore the teeth down a little. So I thought maybe the clutch bearing was the problem and replaced it. Put it all back together and it still did it. I took it back apart and saw it is still rubbing.

My question is what could have got worn to make the two rub? I was thinking I could put a spacer behing the clutch to give it a little more clearance but that really isn't fixing the problem. Its just putting a band-aide on it.

I am looking for a little advice from anyone who may have delt with this already.

 

Anything else worn? Did you pull the shaft to see if it is worn and possibly bent? Tossing out ideas, as I had a similar thing happen on my bike (sort of )

 

Nothing else looks worn or shows wear. I just can't figure out what moved to make the clearance between the two go away?

 

ring gear will have rub marks on it from the stater drive gear

 

I guess "rub marks" was the wrong word for it. It looks more like the ring gear was filed down by a dull file.

 

its been awhile but maybe some one used wrong keyway,just a shot or basket has a crack in it and when drawn up goes to far on shaft?

 

Has anyone figured this problem out ? Did you end up installing a shim to move it back out ?

 

Welcome to the forum!

Hey Tach, we all do this occasionally; responding to an old thread. Been 15 years on this one....
Post an introduction in the Welcome Area thread.
There are a few 1200S owners here as well.