[longstrokeclassic]

I can't remember far enough back when I replaced my pawl to assist with the problem you have now but can I ask that you check the pawl completely closes down before you reasemble the last few parts.

Some of the earlier pawls failed due to incorrect machining tollerances and when the engine ran were always on the ratchet- you cannot hear it beacuase of all the other noises, but if you were to pull a kickstarter down on a jap multi with its engine running you would here the noise I'm trying to describe.

If this was the cause of your failure you will only suffer premature wear leading to pawl failure again if the problem is not corrected whilst you have the chance.

Ric

[Bankerdanny]

The kickstart mechanism and pawl appear to work correctly. I did a test fit before I tried to reassemble and the pawl fit into the top gear fine and the ratching action looked good.