I can’t figure this one out. When I kick the motor over, the teeth of the gears seem to slip—what I call ratcheting or disengaging. The mainshaft is all within specs, and I’ve tried different countershaft gears and shafts. I’ve installed new tripper bolts and assembled and disassembled it so many times that I have all the patience in the world, but I’m still frustrated that I can’t get it to stop ratcheting. Any insight would be appreciated. Thanks.
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The cluster gear and starter clutch teeth must be in good working order without noticable wear. There are 2 springs buried in there. One in the end of the shaft as well as a larger one under the starter clutch. I'd sure look at the small but robust spring in the end of the shaft. This spring pushes the shaft to the right. The spring under the kick clutch pushes it into the cluster gear teeth. If this spring is broken it can also make engagement iffy at best. Do you straddle kick or side kickstart the bike? Before my first rebuild I was given the advise from Rubone to straddle kick the bike as side kicking loaded the shaft in the wrong direction. This worked really well until I went into the gearbox for the last time. By then I had become used to straddle kicking and now side kicking seems so foreign on my 45 yet is somhow second nature on my Shovelhead.
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