Join Date: Sep 2018
Location: West Coast Florida
I'm shooting in the dark here, cuz I don't have an exploded view of the 1100 Sabre shift linkage. But here's where I would start looking. Sounds like you had this issue even before installing the Barnett clutch. From the sound of things, you are only having issues when you up shift to second, but not downshift or going down to neutral. I would start by pulling the clutch and inspecting the end of the shift drum with the shift linkage intact. It sounds to me like the problem is only occurring when the drum is rotating in the up shift direction and only when up shifting into second. But the problem is not occurring when the shift drum is rotating the opposite direction third to second, or second to neutral. To me this would eliminate the 2nd gear engagement dogs and the shift fork (both internal) as the problem. It sounds to me like there may be a wear on the external portion of the drum at the position where the drum is moving neutral to second/second to neutral, so the ratcheting mechanism isn't quite biting enough to upshift through neutral to second. If it is there, that would be the good news. If it is not, the next possibility I would see would be a wear issue on the shift drum chamfer where the 2nd gear shift fork rides, or possible wear on the 2nd gear shift fork itself; if it is either of these, it's a problem requiring a major tear down. Hope you can get it resolved!
If it jams, force it. If it breaks it needed replacing anyway.