After putting the 255s I my 09 Ultra the bike always started hard when hot. Just replaced the starter clutch with an AllBalls starter clutch. Seemed to go in properly and the starter seemed to install properly. Now when I start I can hear the starter clutch gear hanging up on the fly wheel after the engine starts. Not good. Logic tells me if the starter clutch was not fully seated it would actually sit back further and not contact the gear....so that tells me the starter is seated too close to the flywheel and needs to be shimmed out. Seems odd knowing the new starter clutch was the same length as the stock.

What am I overlooking?

Thanks in advance for all replies.

Steve O!

 

Bump - tearing back into it tomorrow night.

Any input on what to be looking for besides anything obvious?

Thanks,

 

Same issue here....what'd you find out? I can't remember how much surface the starter o ring has to seal against on the inner. I feel like 1/16 of an inch is literally all I need!