One hole too many

The link for this is broken in Tech so you can get the 1986 2 stroke Engine manual from http://www.hva-factory.com/catalogue

almost uses the case...but what is important is the relative position of the pawl at rest. 1 spline to far and it causes a nasty back grab when the motor stops. I assume its when it back rotates. its ugly.

http://www.hva-factory.com/files/husqvarna-workshop-manual-2-stroke-engine

the manual was printed 3/86 but pretty much works for all the 2 stroke models 85-88 except there is a clutch nut on 87-88

that is an odd gear number so you can't measure straight across
what is the ID to OD dimension

If I'm measuring right (ID to end of tooth?) it's 9.08 mm. If that's not what you're asking, just let me know and I'll try again.

Well what I'm seeing on mine, is with the kicker shaft in it's "home" position the pawl is held in against the spring holder. See below: Look right?

I got 9.19 on this one so about .030 diff
what's odd is all the primary idler gears are the same, but there are 2 different gear counts on the back gear

looks right to me on that pawl shot.

Yep, you nailed it.

Thanks! If you look close you can see the vice-grips holding a trimmed tongue depressor against the inside of the case which is acting as a backing plate for the JB weld. Just removed it tonight and it looks pretty good. Just need to touch it up with a dremel tool to ensure I've got good clearance.

I wondered what that was

I use doubled aluminum foil as a dam when I do casting with JB. Also apply a thin layer film of Vaseline to the JB surface of the foil so it can be removed after setting and not bond foil to the JB Weld

an easier way is wax paper

Good idea on the foil and wax paper. I thought about a release agent like Vaseline, but was concerned that I would get some of it on the cover and ruin my patch effort. That's why I went with wood that could easily be scrapped away.

i have been using wax paper on everything i glue and clamp for like 30 years, clean-up is a snap

And if you look even closer you'll see that I took jo360's advise because I liked the idea... thanks jo!

Now I gotta go buy some! Thanks premo.

Just be careful not to grind too much off.....

So the one you have won't work, right premo?