Evening Neil
Yes I think we were posting at the same time.
Yes the shim should preferably be hardened, I don’t know where you would get one from, Bearing supplier?
Have touched the bullet on the spring loaded peg with a file and it’s not too hard, so if you can make one fill your boots. It does very little work to be fair.
Whatever you do, do NOT replace the bush in the female shaft with brass it will seize very quickly, use phosphor bronze, you will need to cut the old one out, preferably on a lathe
The ball races in the case, you will need to make a small L shaped tool to get behind the race and produce a small slide hammer, don’t pry off the case it will brake the alloy. Heat the case prior to pulling them out they should not be very tight in the inlay material, Replacement bearings are readily available.
The kick start pawl can be very tight to remove as the operation tightens it on to the thread, Doug Kephart put a post regarding a tool and how to remove this pawl, just at the moment I cannot find it. DOUG CAN YOU POINT US IN THE DIRECTION?
The shaft that you think needs replacing! Take a look on eBay item No 224790373715, it’s not mine so don’t know the condition, but may be a cheaper option than refinishing the original plus you get a couple of other bits.
If you now have four gears I will back off regarding the selector shaft.
Are you looking to rebuild the machine as close to original as possible? Or are you just looking to produce a runner?
Steve