Gearbox Build Problem

I am in the process of putting back together a MK2 Gearbox that I received disassembled and I have a problem. Once it’s assembled with the outer covering place I hear the kickstart ratchet operating when I turn the output shaft. I have about .010” clearance on the kickstart shaft. New bearings have been installed. Any thoughts?

Is the layshaft too tight in the bush inside the kickstart shaft and dragging it around.

Is the 10 thou endfloat and not shaft clearance ?

Layshaft not driven fully home into the bearing?

Check to see that you’ve got all 4 gears meshing correctly. I took a soft mallet to mine (lay and main shafts) and found that neither had seated completely. The layshaft and sleeve gear both moved an additional 10-15 thou after I thought they’d bottomed out...just a thought.