You see ring gears come up on the flea as well as other sources. Not sure that having someone weld up a new ring gear on your old hub is really cost saving though. End of the day I think it is cheaper to buy a new e-start clutch hub that has the ring gear alreay welded in place.

 

I can get a weld on ring gear from J&P for about $55. A new hub is $200.
Hard to even find a good swap meet anymore.

 

Woww 200 large is seriously messed up for just a hub.


Couple on the flea for a whole lot less and include alot more than just the shell itself (50-150)

https://www.ebay.com/itm/Harley-Davi...QAAOSwhO9bYgn1

https://www.ebay.com/itm/Harley-FL-F...AAAOSwzcpbTmCm

https://www.ebay.com/itm/HARLEY-DAVI...wAAOSwofdbVmk2


...and for just the backet for around 30-70

https://www.ebay.com/itm/HARLEY-DAVI...MAAOSwnGJbTUAM

https://www.ebay.com/itm/HARLEY-DAVI...sAAOSw1zpbTT8z

https://www.ebay.com/itm/HARLEY-DAVI...wAAOSwa~JbTUA6

 

thanks to your persuasion I bought a clutch hub shell with ring gear off ebay.
my next question - should I replace the primary chain while I'm at it, or just make sure I can tighten it within specs?
I've already replaced most everything on this bike getting it back in shape, but if it's not necessary I'll save that for another time.

 

BMIKarts shows an 82 link and a 76 link chain for cheap.
https://www.bmikarts.com/search_resu...+chain&search=

 

If high, or Unknown mileage... yes replace.. you oughta see what happens when one lets go!!!!
Good, cheap, insurance while yer right there... IMO

 

I don't recall the outer primary cover that does not have a recessed bearing (flush with the sealing surface) for the pinion gear shaft (jack shaft) but I do know there are at least two outer primary covers with different depth recessed pinion shaft bearings.
As FL454 pointed out, it sounds to me like you have an incorrect outer primary cover for your bike because it is allowing the pinion gear to go too far into the ring gear. Apparently even two thrust washers are not enough.
Is the ring gear on your clutch shell flush with the back of the shell or about 1/4" or 5/16" further onto the clutch shell measured from the back of the shell?

 

Also, it is not hard to replace the ring gear.
The four original welds are cut apart and you can knock the old ring gear off.
I put my clutch shell in the freezer and heated the new ring gear with a torch (an oven would do) and it dropped right into place.
Make sure it is fully in place (seated), then four short evenly spaced welds and that should do it.
If you don't weld, any shop that has a welder can do it for you...should be easy for them.

 

I'm going to install the new clutch shell with ring gear I got off ebay, along with the new All ***** Bendix, and a new Diamond 82 link primary chain I ordered from BMI Karts.
With the clutch and primary chain removed I will install and check the fit of the jackshaft, and make whatever changes are needed.