Hi Pedro and All,
There are two different tooth profiles used on BSA''s and as mentioned they do not mix
Recently I bought a couple of flat or squared off topped pinion gears for customer rebuilds
However the bore on the centre was bigger than the originals
This would lead to the gears being forced apart and possibly jamming as well??
I made new bushes for them to correct the problem as I could not find the flat topped pinions anywhere else
Pedro, who ever told you that the bores should have 7-8 thou clearance needs to be ignored big time
You have the correct clearance
What you have found is that the compression has increased as the rings have bedded in, As it should be
When the engine was worn it was probably very easy to kick over, now its "fixed" it will be harder to kick over
If you pull in the clutch and then engage the kickstart till it goes down a couple of inches (release clutch)
can you then kick the engine over?
HTH
John