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| + | ====== REF: Service Procedures 11E ====== | ||
| + | ====== What Causes the 1991-2003 Shift Arm to Scrub the Starter Gear ====== | ||
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| + | The fact that the shift arm has scrub marks or striations does not mean you have a problem that needs immediate attention. \\ | ||
| + | These marks can be found on most 91-03 Sportsters so it is a very common condition. \\ | ||
| + | Due to the primary cover " | ||
| + | The cover will put the shifter in a different place than you can guesstimate with the cover off. \\ | ||
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| + | There are only small clearances between the detent plate or shift arm from the clutch basket during normal operation. \\ | ||
| + | So normal wear and expanded clearances can cause the markings on the arm. \\ | ||
| + | The slight scoring on the arm should not make a noticeable amount of noise other than a possible intermittent sound from momentary contact. \\ | ||
| + | And you may not be able to hear that over the pipes, especially at higher RPM. \\ | ||
| + | You may be able to help the situation by adding new parts, washers, springs, or checking adjustments and alignments and etc. \\ | ||
| + | But the condition isn't directly related to wear, alignment / adjustment. It's directly related to design. \\ | ||
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| + | The loose clearances will allow for enough slop in the shift chain to let the shift arm " | ||
| + | You'll probably see witness marks on the arm but they should not be deep. \\ | ||
| + | In this instance, the shift arm will rub the ring gear on occasion but not all the time and the witness marks should not be very deep (momentary contact only). \\ | ||
| + | With deep scratches or the shift arm continuously rubs without stopping (permanent contact), check to see if the starter ring gear is backing away from the clutch basket. \\ | ||
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| + | | Witness marks from momentary contact ((photo by Hippysmack)) | ||
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| + | **The starter ring gear is pressed onto the rear of the clutch basket and has been known to slide rearward away from it**. \\ | ||
| + | This may never happen as it doesn' | ||
| + | There are plenty of loose clearances in the shift chain that could cause contact but most of these involve only momentary contact. \\ | ||
| + | But there should be clearance between the shift arm and starter ring gear if you lift the shift shaft to the upper extreme. \\ | ||
| + | A measurement was taken between the arm and gear with a feeler gauge at .043" (1.0922mm) without any scrubbing noticed (shaft lifted up by hand w/ cover off). \\ | ||
| + | This dim is just a dirty one and results will vary. But the point of that measurement is there is that there will be some clearance between the two. \\ | ||
| + | If the arm stays against the ring gear when the shaft is lifted, check the starter ring gear for breakage or slippage. \\ | ||
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| + | | Measuring clearance (results vary) ((photo by Hippysmack)) | ||
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| + | | Correct starter ring gear position ((photo by Hippysmack of the XLFORUM https:// | ||
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