It took us some time to get to it, but I did what Bruce said.
We removed the primary chain, and everything seemed to work fine.
After putting it back together, it didn't work again.
So, we decided to remove two clutch plates because we thought there might be too much tension.
After doing that and reassembling everything, the kickstart didn't seem to work anymore.
It sounds like your mainshaft and sleeve gear are locked together. Possibly the main shaft is too far to the right and when you tighten the clutch nut it will pull the clutch in to the sleeve gear and everything will lock up. Slowly tighten the clutch nut a little bit at a time and see at what point it locks up. Make sure the right side mainshaft ball bearing is fully seated in the inner gearbox cover.
Now has the gearbox on this bike ever worked correctly?
Another possibility is the mainshaft and clutch tapers are worn out and the clutch is going on to the mainshaft too far. Or, the gearbox is assembled incorrectly?
Thank you very much Bruce!
I will check you tips whenI get to it again.
If it ever worked fine, is unknown to me as I got the bikes in parts and put it all together myself.
