I put together my 64 xlch with new parts and notice the kicker engages down a bit further than normal. In the manual there is a running clearance spec of .040 between the faces of the starter clutch gear [kicker gear teeth] and the starter clutch [replacable teeth riveted onto clutch hub]. I have never measured this when putting together a Sportster motor however this distance must be greater than spec to make the crank arm travel farther to engage the teeth. I am sure the spacer was worn and replaced. There are two length[early] spacers listed in service manual. Short 1.025 and long 1.047. If the aftermarket replacement was /is 1.047 then this is[possibly but gotta be] causing the extra travel before engagement of the crank arm. There are two methods to measure for the .040 clearance between the clutch hub's starter teeth . One using math and one using a discarded [ya no such thing] cluth hub with a window cut into it. So the questions does this sound like the problem of the kicker arm engaging lower in the throw? [I guess thats a no brainer] longer space then kicker gear travels further- arm goes dowm more before engaging. And has anyone taken a cut of this spacer on the lathe as in how hardened is it ? I can do the math first to see how much to trim to achieve the .040 spec. I need that extra tooth catching to spin the motor faster with the mag,to ease starting. I used to post here awhile back as dr sportser but new site wouldn't allow it and Panic told me after thirty years of working on Sportsters I didn't know anything. Any replies appreciated even Mr. Diamond.