Need Help With Baja Jackshaft

[Demerest]

I am doing my first rebuild of a Baja Warrior. Having mostly worked on Coleman bikes I have run into an issue with the Baja jackshaft. The outer gear seems to be held in place with a small setscrew which I am assuming is supposed to keep it stationary on the shaft. Trouble is, when I tighten down the outer nut the setscrew doesn’t hold and it pushes the whole gear assembly into the jackshaft bearing and causes it to bind and not turn freely. Am I doing something wrong?

 

[SAT]

You might have to machine some of the sprocket hub material off. Maybe next to the set screw, to allow some clearance when snugging-down the outer bolt. I would do some measuring and figure out where material has to be removed.