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IMO, don't worry about the lip for now, check the mainshaft nut on the other side of the transmission. (#22 mentioned in earlier diagram). It's the left one as your looking at it. You wont be able to see that cast/machined lip unless you take everything apart and remove the large C-clip and bearing.
I think your barking up the wrong tree, your jackshaft is not correct, the 1/8" is right there.
Make sure the coupler is installed correct,
Did you do anything to the starter or solenoid? is the starter spline shaft all the way retracted?
Check the sprocket alignment , if the clutch is out of position 1/8", it should be obvious.
Check the distance to the chain near the compensator, then check it near the clutch, should be within .030"
Thanks Schex, I see your point on the jack shaft and yes I opened and cleaned the solenoid but Im pretty sure I put it all back together properly with the coupler in the right way. At the moment I am reviewing every step again.
the problem though is that the clutch basket is practically touching against the inner primary so its more of a problem of trying to move that away gout Ill review the jackshaft too.
Iill also do the measurement of the chain against the compensatory.
regards the clutch side cover I went in and didnt really see anything was wrong or that I might have moved the main shaft back. Ive attached some photos of what I found and I put a straight edge to both shaft ends and they seem pretty much in line. Nothing is cracked or bearings broken.
my question is what does the sprocket get tightened up against because clearly its going in too far back towards the inner primary. It could still be an alignment issue but I dont see that (I will try tomorrow to loosen everything and see ).
That does look all good on the clutch release side. I just checked it against a hear set I had.. How much clearance do you have from the chain to the inner primary and if you are sure the inner primary is bolted all the way up to the trans as long as you have at least .030" clearance you should be good . Maybe someone with their outer primary off can take a measurement and give you a better idea as for a ballpark amount of clearance..
Schex could very well be right..
Ok Schex I think you might have cracked it!!!
i took off the inner primary off and tried it with the jacksahft set up and you can see in the photo it is a flush fit whereas when installed with the starter in place there is a visible lip which you spotted. Definitely good to have fresh eyes.
So I decided to take the starter off and review if the spline can go back any more. I then remembered if I stalled a new Push button cover on the solenoid. And guess what this was pushing the starter forward by just enough to ruin everything!
I will refit it all in the comm g days and cross my fingers but Im feeling positive!
rha k you gents!!!! And apologies as I should have mentioned the new starter button. Its from Mororcycle storehouse but its too tight at the top! My bad guys.
Absolutely right Hotrod and Yankee Dog (and all the other guys)! Sorry about that, you guys can only analyse what I put out there.
I had just finished the thread on the Starter problem I had just before starting this thread and confused in my head that it was part of the same thread as this!!
I'm still waiting a few days before any celebration as I have to wait for a new Case Saver gasket (this was a massive problem and i don't want to reuse my gasket 3 times!). Also still need to make sure the clutch basket is in the right place when everything is buttoned up. Once i have the gasket I'll double check the fit of the Clutch basket but I hope that'll be it. I'll come back when it's done.
Last edited by monchidog; Feb 24, 2025 at 03:02 AM.
OK I have good and bad news....I refitted it all having made the change to the starter and while it is better the jackshaft does still catch on some turns. So I think the good news is that it probably is a jackshaft issue and I still need to gain and extra few .000" somehow. A quick thought i had, and i know its not the way to go BUT...is to simply put a washer on the end of the jackshaft by the locknut to push the spring into the chamber a fraction. Otherwise I'll have to look at how i can get the spline from the solenoid back in a fraction....I know i havent lost the small ball bearing in there but perhaps something is "stuck".
May go quiet for a few days. Thanks gents.
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