Norton Commando kickstart & gearbox query?

[Grumph]

One other possibility which came to mind is the case gaskets.
If it had gaskets originally between the case and the sandwich piece, and you've simply used RTV or similar - as people do, not condemming - then the layshaft is going further into the kickstart shaft which means it's running on a small area of unworn bush. This could well account for your symptoms.

[Redmoggy]

Once fitted, make sure the bush is reamed to size or you could have the same problem.

Roy