Scooterotica

have you checked that the gears stand proud of the layshaft when fitted, if they dont fit above the end of the shaft you may have a duff gear or layshaft, but end end result is you can never shim the box correctly, i had this on my last build and it was the 4th gear that was too thin, another gear cured it, larger shims are available to 3mm at least, bazza3004 had a good fix of making the slot longer that ive had to do before as well.

I was actually starting to wonder if I had a duff gear or something, I'll see if stickys book tells me how thick each gear should be. I'll get in to it tomorrow, I'm just back from the Aberdeen march of the mods ride-out and I'm away to have a well deserved pint. I'll keep you posted with what I find.