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It sounds like your driving disc is either on the crank too deep (worn crank splines or mis-machined replacement) or the drive gear on operating sleeve has walked off the sleeve. Given you can't remove the drive gear, I'd assume the former. You can test this hypothesis by doing the following: 1) Reinstall Pulley on crank, making note of the drive gear's alighnment with the 1st reduction gear. They should be in constant mesh, close to perfectly aligned. Reinstall actuating fork, making note of any travel in pulley (in or out) when bolts are tightened. If the pulley is forced to move inboard outboard significantly (assuming operating sleeve is free) there could be an issue in the fork mechanism. Do not connect linkage. 2) If #1 checks OK, install the 1st fiber disc and re-install driving disc & torque appropriately. If pulley refuses to move independent from the crankshaft (ie will not spin on its own, or appears to have significant 'drag', your driving disc is likely too far onto the crankshaft. Typically, there will be a 1/8 inch of excess hub extending beyond the crankshaft when seated appropriately. If it is flush, you have a problem in this area. Then, check the crank for excessive wear & test another driving disc, if possible. The new one could be mis-machined, or the crank simply too worn to accomodate it.
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