Transmission Countershaft Thrust Washers. 1979 AMF Harley-Davidson XLH1000 Ironhead Sportster

These things aren't cheap, maybe up to twenty quid a shot although there's probably more than one in a pack. You can get a set of different thicknesses, which is ideal, but only for Evos. Right now I'm leaving the gearbox alone and getting on with the timing side and top end. It's possible I can modify the existing washers, or there may be equivalent items sold as general engineering stock for pennies. I've learnt a lot about the gearbox this time, but this is the point where I have to give myself time to think about the best way forward.

[@warrenp2022]

I'm not recommending this except as a last resort but if the spacer/spacers don't quite correct the problem I might consider gaining clearance by using sandpaper on a flat surface to shorten the dogs enough to clear. Like you seem to prefer, I also like to do repairs correctly until I run into price gouging, then I start getting creative with possible solutions. Hope you get it going again.

[@ImminghamIronhead]

This is an option I'd not considered, but it has potential as it's only a gnats' whisker out. I did think of sanding down one of the washers until they both took up the space, but the gear itself would be way less fiddly.